Manufacturing Data Analytics
From shop floor to boardroom, powered by a single source of truth
We build the data infrastructure that powers tiered daily management in manufacturing. OEE dashboards, quality analytics, predictive maintenance, and executive reporting, all drawn from one data warehouse that mirrors how your factory actually communicates.
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Manufacturing Analytics Services
OEE Dashboards and Production Analytics
Real-time and shift-level Overall Equipment Effectiveness tracking broken down by availability, performance, and quality. Identify losses by line, product, and shift with automated data collection from MES and ERP systems.
Quality Analytics and SPC
Statistical process control charts, defect Pareto analysis, cost of poor quality (COPQ) tracking, and CAPA aging reports. Connect quality data to production lines, materials, and suppliers to find root causes faster.
Predictive Maintenance
Move from reactive to predictive. We build models using sensor data, vibration analysis, and historical failure patterns to forecast equipment breakdowns before they cause unplanned downtime.
Tiered Meeting Dashboards
Analytics designed around your daily management structure. Shift-level dashboards for Tier 1 handovers, cross-functional views for Tier 2, departmental deep-dives for Tier 3, and plant-level executive summaries for Tier 4.
Manufacturing Data Warehouse
A single source of truth that consolidates ERP, MES, SCADA, quality, maintenance, and warehouse data. Clean, governed, and structured to power every level of reporting from shop floor screens to boardroom reviews.
Lean Six Sigma Analytics
Data infrastructure that supports DMAIC projects end-to-end. Process capability indices (Cpk), control charts, and validated savings tracking that feeds directly into your continuous improvement programme and tier meeting cadence.
Maintenance and CMMS Analytics
MTBF, MTTR, planned vs unplanned maintenance ratios, spare parts consumption trends, and equipment reliability dashboards. Make maintenance data actionable instead of buried in work order systems.
Production Planning and Scheduling Analytics
Plan adherence tracking, changeover time analysis, cycle time monitoring, and capacity utilisation reporting. Compare planned vs actual output to identify scheduling gaps and improve throughput.
Multi-Plant Benchmarking
For organisations running multiple sites, we build the federated data layer that enables cross-plant OEE comparison, regional scrap benchmarking, and portfolio-level Six Sigma project tracking aligned with STRAP and AOP targets.
Manufacturing Case Studies
Explore real projects where we delivered measurable outcomes in this industry.
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Your Goals, Our Expertise
We start from your strategic objectives and work our way back to the right mix of solutions and technologies, not the other way round.
Book a Consulting CallOur Approach to Manufacturing Analytics
We start by understanding your daily management cadence: who meets, when, and what questions each tier needs answered. The analytics architecture mirrors this communication structure.
We connect your ERP, MES, quality, maintenance, and warehouse systems into a single data warehouse. Clean transformations, consistent definitions, one source of truth.
We deliver dashboards for each tier simultaneously, starting with the shop floor and executive views. Same data, different lenses, designed for the questions each audience actually asks.
We add alerting, automated reports, and advanced analytics. Once the tier meetings run on dashboards instead of spreadsheets, we extend to predictive maintenance, SPC automation, and multi-plant benchmarking.
We start by understanding your daily management cadence: who meets, when, and what questions each tier needs answered. The analytics architecture mirrors this communication structure.
When Do You Need Manufacturing Analytics?
- Your tier meetings run on spreadsheets pulled manually from different systems each morning.
- OEE is calculated differently across shifts, lines, or plants, and no one trusts the numbers.
- Scrap and quality data lives in the quality system but never connects to maintenance events or supplier batches.
- The plant director sees a monthly report but shift leaders have no real-time visibility into their own performance.
- Lean Six Sigma projects build their own datasets from scratch instead of pulling from a central source.
- Multi-plant organisations cannot benchmark performance because each site defines metrics differently.
Why Choose Witanalytica for Manufacturing Analytics?
Manufacturing Operations Experience
Our team has worked inside manufacturing plants, in rotational programmes and process improvement roles. We understand tier meetings, Lean Six Sigma, and the daily rhythm of a factory floor.
Full-Stack Data Capability
From raw ERP/MES data extraction through warehouse design, ETL pipelines, and BI dashboards to predictive models. We handle the entire analytics stack, not just the reporting layer.
System Agnostic
SAP, Oracle, Microsoft Dynamics, Infor, custom MES, Siemens, Rockwell SCADA. We integrate data from any combination of manufacturing systems into your analytics environment.
Lean Six Sigma Aligned
Our analytics infrastructure supports DMAIC projects natively. Control charts, process capability studies, and validated savings tracking draw from the same warehouse that powers daily operations.
Operational Focus, Not IT Focus
We treat analytics as an operations project that uses technology, not a technology project that happens to serve operations. KPI definitions are owned by your operational teams.
Flexible Engagement Models
Whether you need a one-time data warehouse build, an ongoing analytics retainer, or a dedicated team embedded in your operations, we structure engagements around your needs.
Our Manufacturing Analytics Pricing Models
We offer flexible engagement options tailored to your project scope and business needs.
Time and Material
Suited for projects where scope may vary, this pay-as-you-go option offers flexibility to adjust requirements as your project evolves. We estimate effort upfront and ensure transparency in billing.
Retainer Fee
For ongoing analytics needs, our retainer service provides dedicated support for a set number of hours each month. Secure our availability without the commitment of a full-time hire.
Dedicated Resources
For consistent, high-volume workloads, we provide a team or individual fully focused on your analytics needs for a sustained period — offering stability and deep integration with your operations.
Manufacturing Data Analytics FAQs
We work with discrete and process manufacturers across automotive, aerospace, food and beverage, consumer goods, chemicals, and industrial equipment. The analytics methodology applies regardless of what you manufacture.
Yes. We build integrations with SAP, Oracle, Microsoft Dynamics, Infor, and custom ERP systems, as well as MES platforms like Siemens Opcenter, Rockwell Plex, and AVEVA. We consolidate all sources into a central data warehouse.
It is an analytics architecture where each level of your daily management structure gets its own dashboard view. Tier 1 (shift handovers) sees granular, real-time data. Tier 2 (cross-functional technicians) sees daily summaries across maintenance, quality, and logistics. Tier 3 (department reviews) sees weekly trends and root cause analysis. Tier 4 (plant leadership) sees plant-level KPIs against AOP targets. Tier 5 (regional operations) sees multi-plant benchmarking against STRAP objectives.
Yes. Our data warehouse and dashboards are designed to support DMAIC projects directly. Measure and Analyse phases pull from the warehouse. Control charts and process capability studies are built into the reporting layer. Validated savings are tracked and visible at every tier.
For multi-plant organisations, we build a federated data layer or common semantic model that normalises data across different ERP instances, MES systems, and local definitions. This enables cross-plant benchmarking with consistent KPI definitions.
We primarily work with Power BI, Tableau, and Grafana (for real-time shop floor displays). Tool selection depends on your existing infrastructure, refresh rate requirements, and team capabilities.
Inbound logistics, warehouse operations, and outbound shipping are integral functions inside a manufacturing plant and are included in our manufacturing analytics scope. We track supplier on-time delivery, inventory levels, warehouse accuracy, and OTIF performance as part of the tiered dashboard system.
Access to your ERP system (production orders, BOMs, financials)
MES or production tracking data (if available)
Quality system data (inspection results, non-conformances)
Maintenance system data (work orders, downtime logs)
Warehouse/inventory data
Your current KPI definitions and meeting structure
We offer Time and Material, Retainer Fee, and Dedicated Resources models. Manufacturing analytics projects typically start with a discovery and data audit phase, followed by iterative warehouse build and dashboard deployment.
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