Brembo used Kepware to connect legacy machines, PLCs, production lines, and disparate sources of process data. ThingWorx provided a centralized data hub that aggregated information across servers and displayed plant-level, regional, and corporate-level views.
The company began with a three-line pilot and followed a phased approach to a full facility rollout. Within 10 weeks, it implemented a real-time production performance monitoring use case. Production data was presented through three custom dashboards, giving different user groups access to real-time, actionable information, drill-ins, alerts, and process-flow pop-ups that helped operators troubleshoot issues as they occurred.
To support continuous improvement, Brembor established clear responsibilities and close collaboration between IT and OT. Shared data helped improve visibility into line operations, strengthen troubleshooting, increase operational efficiency, and prioritize initiatives capable of creating meaningful change.
Following the pilot, the company expanded its use cases across production. Kepware and ThingWorx supported analysis of cycle time, downtime, and first-pass yield to improve overall equipment effectiveness. The solutions were also used to monitor assets, identify unplanned downtime, reduce unnecessary energy use, track production information for compliance, and integrate line data with enterprise resource planning financials.
Rather than creating one-off solutions, the team designed reusable models that could be applied across scenarios with minimal changes. Standard naming conventions, repeatable processes, configuration backups, and change-management controls enabled successful configurations to be replicated across the enterprise. Through this scalable approach, Brembo expanded from three production lines to 75.
