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Manufacturing · Data Engineering & Analytics

Lakehouse data platform and OEE analytics for a textile manufacturer

A multi-plant textile manufacturer had production data locked in PLC historians, an ERP and spreadsheets, with no single view of equipment effectiveness.

Stack Databricks · Azure Data Factory · Kafka · dbt · Power BIDuration 5 monthsTeam 6 engineers
5 minfrom event to dashboard (was 2 weeks)
+6 ptsOEE improvement on the two pilot lines in the first quarter
1governed source of truth across six plants
~40%less manual reporting effort

The challenge

Six plants, three ERP instances and machine data arriving at different frequencies. Plant managers reconciled numbers by hand every Monday; leadership saw results two weeks late.

What we did

Medallion lakehouse on Databricks with bronze/silver/gold layers and data contracts per source
Streaming ingestion of machine events via Kafka; batch ERP loads via Data Factory
dbt models for OEE (availability × performance × quality), scrap and energy per lot
Data quality monitors, lineage and a governed semantic layer for Power BI
Plant-floor dashboards on wall displays refreshed every 5 minutes
“Our plant heads now open Monday reviews with the same numbers — that alone changed the conversation.”
— Client sponsor (name withheld under NDA)

Engagement facts

IndustryManufacturing
ServicesData Engineering & Analytics
TechnologyDatabricks · Azure Data Factory · Kafka · dbt · Power BI
Duration5 months
Team6 engineers

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Details are anonymised and figures rounded to protect client confidentiality.

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Kunal Bearings

Global IT services and cloud-native engineering, with a precision thin-section bearings manufacturing division. Headquartered in Ahmedabad, India.

IT Services

Global Capability Centers Cloud-Native Engineering DevOps & Platform Engineering Data Engineering & Analytics AI & Intelligent Automation Agile Product Engineering

Products

Thin Section Bearings (KB-A to KB-G) KB-U 2RS Sealed Series Tapered Roller Bearings Textile Rotary Printing Bearings Browse the store

Contact

307 Anand Chambers, Near High Court Crossing, Navrangpura, Ahmedabad, Gujarat 380009, India

info@kunalbearings.com

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REX INREX0802004962EC004 · LUT AD2407210055976

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