Is your digital initiative stuck in pilot mode?
Learn how to move from tactical wins to strategic Smart Manufacturing in our latest whitepaper.
Smart Manufacturing & Chordata
Problem
A global supplier of paints, coatings, optical products, and specialty materials was operating with legacy automation hardware that limited visibility into production performance and constrained future digital initiatives. The existing infrastructure did not provide the real-time data collection or KPI tracking capabilities required to support OEE monitoring, waste analysis, or enterprise-level reporting. As a result, production systems could not be easily monitored, benchmarked, or integrated into higher-level analytics platforms aligned with corporate’s broader digital manufacturing roadmap.
Compounding the challenge, the facility’s network architecture did not allow direct data collection from existing machine PLCs. This created a technical barrier to establishing consistent and reliable KPI measurements across the production line. Without a standardized method for collecting and contextualizing production data, leadership lacked actionable insight into throughput, downtime, scrap, and process bottlenecks.
The site required both a technical foundation and a strategic roadmap to align operational improvements with business drivers and measurable KPIs.
Proposed Solution
Polaris Automation began the engagement by conducting a Smart Manufacturing Roadmap assessment using the CESMII framework. This structured approach enabled a comprehensive evaluation of the current state and definition of a desired future state. Together with site leadership, Polaris developed an iterative roadmap designed to create measurable value in each phase while building toward a scalable digital manufacturing foundation.
For the first phase of the deployment, the team implemented a stand-alone Chordata production tracking solution designed to bypass existing network constraints. A Polaris-installed PLC, along with Polaris-specified sensors, was deployed to collect product counts at key points along the paint can production line. This approach established an independent and reliable data acquisition layer without requiring immediate modification to the legacy control systems.
The initial implementation focused on collecting foundational production KPIs, including:
- Total production counts
- Cans per minute (CPM) with historical trending
- Blocked and starved conditions at multiple line locations
- Total scrap and waste at defined process points
Chordata dashboards were configured to provide real-time visualization of these metrics for operators, supervisors, and leadership. For the first time, the facility gained immediate visibility into line performance, enabling data-driven discussions around downtime, throughput, and waste reduction. The implementation from start to finish only took a matter of weeks.
This phase was intentionally scoped to establish a technical and cultural foundation – introducing standardized KPI definitions, consistent data collection methods, and visual performance management tools that support continuous improvement initiatives. Future phases will build upon this foundation by integrating data from a broader range of equipment and systems, enriching context, and establishing a Unified Namespace (UNS). A UNS enables seamless data sharing across all levels of an organization by creating a single, centralized source of truth – reducing silos, improving real-time visibility, and allowing teams to make faster, more informed decisions.
Outcome
This solution successfully delivered real-time production visibility to the facility, creating a measurable shift in operational awareness and accountability.
Leadership and operations teams can now:
- Identify and categorize downtime events
- Monitor throughput and CPM trends in real time
- Quantify scrap and waste at specific points in the process
- Detect blocked and starved conditions that impact overall efficiency
With reliable data in place, the facility has begun initiating targeted continuous improvement projects focused on throughput optimization and waste reduction. KPI-driven decision-making has replaced anecdotal assessments, enabling more structured problem-solving and measurable performance gains.
Equally important, this implementation established the technical infrastructure required for broader digital initiatives. By deploying an independent data collection architecture, the site overcame legacy network limitations and created a scalable platform for future integration with enterprise systems and advanced analytics.
From a strategic perspective, the Smart Manufacturing Roadmap provided alignment between business drivers, operational KPIs, and long-term digital goals. The engagement not only addressed immediate visibility challenges but also positioned the facility to align with corporate’s connected enterprise vision and expand Chordata capabilities both at this site and across additional facilities.
This phased approach demonstrates how targeted, foundational investments – guided by a structured roadmap – can deliver immediate operational value while building toward a standardized, enterprise-wide digital manufacturing strategy.
Testimonial
“We partnered with Polaris to implement a MES solution to help improve productivity and reduce waste. They have been great in both helping to strategize an optimal system, and with their technical skills to install, configure and connect the various components needed to modernize our manufacturing environment.”
