Velonex (Ratnaudyog)
Manual tracking overstated OEE (79% vs. actual 57%) across diverse CNC controllers, hiding bottlenecks. Velonex delivered live shop-floor data enabling immediate corrective action.
Problem Statement
RatnaUdyog needed to boost throughput and cut overheads within existing capacity, but unified tracking was hindered by 5 machines ranging from 1 to 10 years old with diverse CNC controllers like Mazatrol and Fanuc. Furthermore, manual OEE tracking concealed true operational losses by generating overly optimistic performance metrics that misled management. Without real-time visibility into machine downtime, the company could not systematically identify bottlenecks or make data-driven decisions to increase productivity
Solution
Velodynamics deployed Velonex an Industry 4.0 monitoring system offering 24/7 OEE tracking and designed two hardware approaches (Siemens-PLC with HMI and TID via RS-232/Macro-B). To test the technology, RatnaUdyog launched a pilot connecting three top-performing machines using the TID approach via LAN to a centralized computer. This setup delivered continuous real-time data to PCs, tablets, and mobile devices, empowering operators and managers to take immediate corrective actions on the shop floor.
Functionalities
Overall Equipment Effectiveness (OEE)
Overall Equipment Effectiveness (OEE): Tracks true productive manufacturing time, pinpoints underlying losses, and guides systematic process improvements.
Statistical Process Control (SPC)
Live performance monitoring that detects process shifts before non-conforming products or scrap are produced.
Product Traceability
Automated real-time tracking of product location, status, and availability across manufacturing stages via Barcode, QR Code, RFID, or Laser Engraving.
24/7 Remote Visibility
Real-time dashboards and analytics accessible anytime from PCs, tablets, or mobile devices across the globe.
Tech Stack
Layer
Technology Stack
Frontend
Angular
Backend
.Net core 8
Database
MSSQL
Cloud & Hosting
Amazon Web Services
Notifications & Services
Firebase Cloud Messaging (Mobile Application) / MessageHUB / SignalR
Impact on Client
Exposed True OEE
Within 8 months, Velonex revealed that the actual OEE was 57%, debunking the manual, overly optimistic estimate of 79%.
Immediate Capacity Recovery
Real-time alerts allowed fast, corrective actions on the shop floor, preventing critical loss of production hours.
Minimized Waste & Cost
Shorter rework loops and reduced scrap directly reduced unit manufacturing costs and raised overall plant profitability.
Testimonials
"Velonex has made tracking line performance and shift downtimes effortless, giving us full visibility over every cycle even during busy night shifts. Logging issues and monitoring production output in real time allows our operators to tackle delays instantly and keep the line moving smoothly. Velodynamics’ reliable platform and proactive support have made a huge difference in how efficiently we manage our day-to-day shop floor operations."
Wasim Sheikh
Line Supervisor
ZP
April 2021
