Automotive · Mobility

Holding equipment flow and
quality steady, with data

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Challenges on automotive sites

Recurring problems across press, body, paint and assembly.

One process shakes the whole line

Press, body, paint and assembly are coupled end to end, so a single piece of equipment going wrong spreads into a full line stoppage.

High power and fine control at once

Heavy-draw equipment and precision control share the same line, so tuning one side unsettles the other.

Equipment, energy and output stay apart

Electrification and tighter quality standards demand all three together, but the data sits in separate systems.

Representative use cases

What Refinery
actually does
on an automotive site.

Vibration-based predictive maintenance

Problem
Rotating-equipment faults confirmed only after a stoppage
Approach
An AI agent reads anomalies in vibration and current trends to catch early signs, and proposes both the likely cause and the next action with the history behind it.
Outcome
Less equipment downtime and steadier production

Power usage patterns by line

Problem
Different power draw line to line, with no way to explain it
Approach
Lines, processes and assets are connected through an ontology, giving every signal a meaning, so power use can be compared on equal terms.
Outcome
Lower energy cost and inefficient processes identified

Demand-based compressed air control

Problem
Air compressors running regardless of actual demand
Approach
Power draw and operating patterns are read so a VSD matches supply to demand, with inspection cycles and fault diagnosis managed alongside.
Outcome
Minimal energy waste and better operating efficiency

Energy intensity tied to output

Problem
No structure for seeing efficiency against production
Approach
Production records and energy use are linked to derive intensity by line and model automatically.
Outcome
Efficiency made visible against output, cost structure improved

Ambient conditions and quality impact

Problem
Causes of quality issues recorded apart and hard to retrace
Approach
Temperature, humidity, equipment state and quality results are joined on one timeline to trace the cause.
Outcome
Less quality variance and better process conditions

How it fits together

How site data gains meaning and turns into a decision.

Site
  • Press, paint and assembly equipment
  • motors
  • vibration sensors
Connect
  • SCADA
  • PLC
  • MES
  • Modbus TCP⁠/⁠IP
  • RS-485
  • OPC-⁠UA
Refinery
  • Ontology
  • AI agent
  • rules and automation
Use
  • Line dashboard
  • maintenance alerts
  • quality traceability

Where MES or PLC already exists, Refinery sits on top of it and integrates both ways rather than replacing it. Where none exists, collection is built from the ground up.

Systems we connect to

The systems and protocols commonly used on automotive sites.

SCADAPLCMESERPModbus TCP⁠/⁠IPRS-485OPC-⁠UALTE

Systems not listed here can still be connected over standard protocols and APIs. Get in touch and we will walk through it.

What you gain

Benefits across operations, engineering and management.

Less equipment downtime

Faults are caught early in vibration data, keeping production steady.

Lower energy cost

Power patterns are compared line by line to identify inefficient processes.

Better cost structure

Efficiency against output is put into numbers.

Less quality variance

Ambient conditions and quality results are joined to tune process settings.

Let’s find the answer that fits
your automotive operation, together.

Request a demo