Real-time intelligence with Microsoft Fabric: A deep dive into the manufacturing industry
It might surprise you to learn that unplanned downtime can cost manufacturers up to $260,000 per hour, as highlighted by industry research on IIoT World. Leveraging real‑time intelligence is key to preventing these costly disruptions. In the fast-paced world of the manufacturing industry, real-time intelligence is not just a luxury - it’s a necessity. With increasing demands for efficiency, sustainability, and precision, the ability to process, analyze, and act on data in real-time has become a game-changer. In this blog, I’ll share insights from a recent project that challenged our team to rethink how data can solve operational bottlenecks while addressing a critical hurdle: ensuring adoption by shopfloor operators.
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So, why is real-time intelligence such a game-changer? Because in today’s data-driven world, reacting quickly is no longer enough - businesses need to anticipate and act before issues arise. Real-time intelligence empowers businesses to make informed decisions instantly, and in the manufacturing industry, this can translate into:
Real-time intelligence: Why it matters
- Minimized downtime: Proactively resolving equipment issues before they escalate.
- Optimized production: Adjusting parameters in real-time to meet fluctuating demand.
- Improved quality control: Detecting defects instantly, reducing waste by 15-20% in pilot phases.
In this particular project, Microsoft Fabric’s ability to integrate real-time data streams from diverse sources and deliver actionable insights was the cornerstone of achieving these outcomes.
A real-life implementation: manufacturing case
Our client, a global manufacturer, was striving to keep up with increasing production demands while minimizing downtime and waste. They were hindered by three critical challenges:
- Fragmented data systems: Insights were delayed due to siloed systems that couldn't communicate effectively with each other.
- Costly downtime: Maintenance was reactive, leading to high downtime costs that significantly impacted profitability.
- Technology resistance: Shopfloor teams were accustomed to manual processes and sceptical of adopting new systems.
To address these challenges, our team collaborated closely with our customer to develop a data-driven solution tailored to their needs. As a Data Engineer on this project, my responsibilities included:
- Data modelling: I designed star-schema models to structure real-time machine data, enabling efficient analytics and simplifying complex datasets for actionable insights.
- API development: To bridge the gap between systems, I built RESTful APIs that connected SAP with Fabric’s EventHouse via MQTT and EventHub, ensuring seamless data flow and system interoperability.
- Data governance: Establishing a "single source of truth" was critical. I standardized data definitions and validation rules, ensuring analysts could rely on consistent and accurate information.
- Real-time intelligence management: I oversaw the end-to-end management of Fabric’s real-time data pipelines, optimizing performance to achieve sub-500ms latency for critical alerts and notifications.
Elevating operational efficiency
We began by connecting IoT data sources, including machine data from Kepware, Ignition, MQTT, and EventHub to Fabric’s EventHouse (Kusto Database). This integration enabled centralized and processed over 12,000 data points per minute, creating a unified data foundation critical for real-time insights.
However, working with legacy systems presented a unique challenge. Many lacked APIs, requiring us to develop custom connectors to ensure seamless data flow between systems.
By building intuitive real-time dashboards, we provided operators with live insights into line performance, enabling immediate corrective actions. These real-time dashboards are like having Google Maps for your production line - know where the traffic jams are before you’re stuck in them.
With this current integration, workers also gained access to real-time safety protocols and training modules directly on the factory floor. This integration could reduce incident rates by up to 25% and increase overall safety awareness.
The potential impressive results of this impact could include:
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The result is a robust, integrated solution that empowered operators with real-time insights while reducing reliance on outdated, manual processes. By addressing both the technical and human aspects of implementation, we are able to ensure the solution's success across all levels of the organization.
Key features of Microsoft Fabric in action:
As mentioned, Microsoft Fabric played a central role in transforming how data was collected, processed, and utilized. By leveraging its robust capabilities, the solution we built not only enhances operational efficiency but also fosters collaboration and improved safety. Here are a few key features of Microsoft Fabric and how they came to life in this implementation:
Unified data architecture
Fabric’s seamless integration across data pipelines allows for real-time ingestion and processing of data from machines via Kepware, integrated with Ignition, and then transmitted through MQTT to EventHub before being ingested into Fabric’s EventHouse (Kusto Database). This setup enabled us to capture machine performance and production data efficiently.
Think of your data pipeline as your internet connection - faster is better, but reliability is key. Don’t let your data packets “buffer.”
Real-time analytics
With Fabric’s Synapse Real-Time Analytics capabilities, we processed high-velocity data streams to identify bottlenecks and enhance production monitoring.
If you’ve ever waited for a 10GB file to upload, you’ll appreciate why low-latency analytics feels like upgrading from dial-up to fiber optic.
Collaborative workflows
Fabric’s unified platform brought together data engineers, analysts, and domain experts, fostering collaboration. This streamlined workflows and accelerated decision-making during the implementation phase.
It’s like having all your teammates in the same Slack channel - minus the memes (but we wouldn’t complain if Fabric added that feature).
Integration for operational health and safety
In a key enhancement, we integrated a solution into our operations to support health and safety initiatives. This solution’s digital platform provided real-time access to training materials, incident reporting, and safety updates, ensuring a safer work environment and boosting compliance.
Treat your safety data like an IT backup - always accessible and updated, because you never know when you’ll need it.
Personal insights: The real impact of real-time intelligence
Working on this project was both challenging and rewarding. In my role I had the opportunity to design scalable data models and build integrations that truly made an impact on real-world operations. One of the biggest "aha" moments for me was seeing how real-time intelligence isn't just about technology - it's about changing the way people work.
Initially, shopfloor operators were sceptical of the real-time dashboards, preferring their manual tracking methods. Instead of forcing adoption, we took another approach and worked closely with them to understand their workflows, address their concerns, and gradually demonstrate how real-time data could make their jobs easier rather than more complicated.
Another key takeaway was the power of unified data architecture. Bringing together IoT, SAP, and Microsoft Fabric into a single, streamlined pipeline not only reduced downtime but also improved decision-making at every level - from operators on the floor to leadership teams analyzing trends.
At Nortal, we don’t just build solutions - we rethink how technology integrates into business workflows. Seeing our work result in 18% downtime reduction and a 30% increase in operator efficiency made all the long hours and problem-solving absolutely worth it. If you’re passionate about data, problem-solving, and making a real impact, Fabric and Nortal provide an exciting playground to do just that!
While Microsoft Fabric transformed our client’s operations, the human element was truly the key to success in this project. By blending technical expertise with empathy for end-users, we turned resistance into enthusiasm. As one operator remarked, “Now I can actually fix problems before my shift ends.” So, in conclusion, with this project we’ve proven that real-time intelligence isn’t just about data - it’s about empowering people.
Conclusion
As with all architectural decisions, the platform approach has trade-offs, and it is impossible to recommend a one-size-fits-all approach. Well-executed platform architecture can offer multiple benefits, such as accelerated delivery, TCO per application, and consistent user experience. On the other hand, the platform has lifecycle costs, requires good engineering skills, and it is not easy to calculate the ROI beforehand. However, by focusing on measurable outcomes and continuous improvement, you can demonstrate the value of your platform over time.
To start your platform journey, it's crucial to approach platform development strategically and understand your organization's specific needs and goals. By starting small, focusing on measurable outcomes, and prioritizing alignment between technology and business, you can harness the full potential of platform engineering and build a foundation for sustainable growth. With the rise of AI and automation, platforms will become even more intelligent and adaptable, further streamlining development and operations.
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Nortal is a strategic innovation and technology company with an unparalleled track-record of delivering successful transformation projects over 20 years.