At Eleven Tech Industrial Solution Limited, we pride ourselves on taking on projects that challenge us to push the boundaries of engineering innovation. One such project was an automation upgrade for a large manufacturing plant based in Mbeya. In this case study, we’ll walk you through the process, challenges, and results of transforming a traditional factory floor into a high-efficiency, automated powerhouse.

The Client’s Challenge:

The manufacturing plant had been struggling with several operational inefficiencies, including:

• Frequent equipment downtime due to manual processes and outdated systems.
• Lack of real-time monitoring of equipment performance.
• Increased energy costs from inefficient machines and processes.
• Safety hazards due to inconsistent maintenance and oversight.

The Solution:

Eleven Tech was tasked with integrating an industrial automation system that could solve these problems and transform the plant’s operations. Our approach included:

1. System Integration:

We installed Programmable Logic Controllers (PLCs) and Human-Machine Interfaces (HMIs) that enabled seamless communication between machinery and central control systems.

2. Predictive Maintenance:

Our team implemented sensors across critical machines to monitor performance in real-time and predict failures before they happened. This led to a significant reduction in unplanned downtime.

3. Energy Efficiency Improvements:

We integrated smart energy meters and control algorithms to optimize energy usage across the plant. This helped the plant reduce energy consumption by 15% within the first month.

4. Data Monitoring and Reporting:

By using SCADA (Supervisory Control and Data Acquisition) systems, the client gained full visibility over their operations. Data insights were gathered from various machines, which helped the team make data-driven decisions to improve production schedules.

Overcoming Key Challenges

Every successful project comes with its share of challenges. For this plant, some of the hurdles we faced included:

• Integrating new technology with old infrastructure: Many of the plant’s machines were old and not designed for digital integration. Our team worked closely with the client to retrofit legacy equipment to communicate with the new system.
• Training the workforce: Transitioning to automated processes required a change in mindset. We conducted workshops and hands-on training for the factory workers and engineers to ensure they were comfortable using the new systems.
• Tight project deadlines: The client needed to complete the upgrade while minimizing disruption to daily operations. Our team worked tirelessly to meet the project deadlines without compromising quality.

The Results:

After three months of installation and fine-tuning, the plant experienced impressive improvements:

• Reduced downtime by 30% due to predictive maintenance.
• Energy costs decreased by 15%, thanks to more efficient systems and real-time monitoring.
• Production capacity increased by 25%, resulting in a higher output with fewer manual interventions.
• Employee safety improved as automation took over risky manual tasks, and the monitoring system ensured compliance with safety protocols.

Why Choose Eleven Tech for Your Next Project?

This project highlights how we at Eleven Tech combine cutting-edge technology, expertise, and dedication to quality to deliver real-world solutions for our clients. Whether it’s energy optimization, safety improvements, or system integration, we’re equipped to handle even the most complex challenges in the industrial sector.

“Working with Eleven Tech has been a game-changer for our operations. We’ve seen tangible improvements in efficiency, safety, and costs. We can now focus on growing our business instead of worrying about downtime.”
– Manufacturing Plant Manager, Mbeya

Contact Us for a Custom Solution

Ready to modernize your industrial operations? Reach out to Eleven Tech and let’s discuss how we can make your systems smarter, safer, and more efficient.

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