Manufacturing Performance Optimisation

A Melbourne-based manufacturing company lacked real-time visibility into production efficiency and the key drivers of operational downtime. Production data was distributed across several operational systems, including ERP platforms, manufacturing execution systems (MES) and maintenance management tools. Because these systems were not integrated, leadership and plant managers struggled to obtain a clear and consistent view of manufacturing performance across production lines.

Operational reporting relied heavily on manually prepared spreadsheets compiled from multiple data sources. This process was time consuming and often delayed, making it difficult for operations teams to identify performance issues as they occurred. Without real-time insights into equipment performance, downtime events and production efficiency, management teams were unable to proactively address operational inefficiencies or optimise production capacity.

Roar Data implemented a structured Power BI manufacturing analytics solution designed to integrate operational data across the organisation. ERP, MES and maintenance systems were connected into a unified Power BI data model that standardised production metrics and created a single source of truth for manufacturing performance.

Executive and operational dashboards were developed to provide real-time visibility into overall equipment effectiveness (OEE), production output, downtime drivers and maintenance performance. These dashboards enabled plant managers and leadership teams to identify downtime root causes, monitor production efficiency and align operational KPIs across the manufacturing environment.

Following implementation, the organisation achieved an 18% improvement in overall equipment effectiveness and reduced production downtime by 22% within six months. The new Power BI dashboards allowed operations teams to move from reactive reporting to proactive performance management across the production floor.