Project Overview
A mid-size Japanese auto parts manufacturer based in Aichi Prefecture, with approximately 500 employees and three production facilities, approached BCT Global to modernize their manufacturing operations.
The Challenge
The client's manufacturing operations relied on a legacy MES that was over 12 years old. Quality control processes were still paper-based.
- 15% defect escape rate due to delayed quality reporting
- No real-time view of equipment performance
- Monthly reporting took 2 weeks to compile
- Data silos between factories
- Growing pressure from OEM customers for digital traceability
Our Solution
- Phase 1 — IoT Infrastructure (Months 1-4): Installed 200+ IoT sensors across three factory floors for real-time data collection.
- Phase 2 — Dashboard & Analytics (Months 4-9): Built custom React-based dashboard with OEE monitoring and predictive analytics.
- Phase 3 — Cloud Migration & Integration (Months 9-14): Migrated legacy MES data to AWS, integrated with SAP ERP for seamless operations.
System Architecture
Technology Stack
Results & Impact
40%Reduction in Downtime
3xFaster Reporting
8 moROI Achieved
60%Defect Rate Reduction
"BCT Global's team integrated seamlessly with our factory operations. Their bilingual project manager understood both our technical requirements and the nuances of Japanese manufacturing culture. The fact that they are ISO 27001 and ISO 9001 certified gave us confidence from day one, especially when handling our proprietary production data under APPI compliance."
Director of Manufacturing TechnologyJapanese Auto Parts Manufacturer — 500+ employees, Aichi Prefecture