🚀 Case Study: End-to-End Production Automation in Manufacturing Plants

Sector: Industrial Manufacturing
Role: Lead Embedded Systems Engineer
Client Impact: 300% output growth, multi-million pesos profits and cost savings

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🎯 Objective

To eliminate critical production bottlenecks and unlock scalable output for a major manufacturing client.

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⚠️ Challenge

The client faced significant constraints across four automated production lines:

• Inaccurate raw material dispensing
• Rigid, high-cost PLC-based systems
• Complex interfaces unsuited for non-technical operators

These problems limited production throughput, reduced quality, and directly impacted profitability.

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🧩 Solution

As the sole embedded developer, I designed and delivered a full-stack IoT automation system—custom-built from firmware to frontend.

System Features:

• Custom Embedded Backend (C): Low-level, real-time control logic using Unix domain sockets and TCP/UDP for hardware communication.
• Proprietary Hardware: I engineered and sourced custom PCBs, replacing expensive PLCs with cost-effective in-house alternatives.
• Novel Integral Algorithm: Solved a complex weighing challenge, enabling multi-line, simultaneous dispensing with high precision.
• User-Centric SCADA Interface: Built a modern, intuitive UI for real-time monitoring, accessible even to users with no prior computer experience.
• Full Software Stack: Integrated scheduling (CRON), database (MySQL), firmware control, and operator visualization into one seamless, fault-tolerant platform.

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📊 Impact

• 🚀 Production throughput increased by over 300%
• 🎯 Achieved near-perfect dispensing accuracy
• 💰 Tens of millions in new profits generated
• 🏭 Tens of millions in operational savings realized
• ⚙️ Zero critical failures over 5+ years in production

This solution didn’t just optimize a process—it reshaped the client's entire production model.

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🧪 Technical Stack

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🧠 Key Takeaways

Great automation isn’t just about precision—it’s about designing systems that are scalable, intuitive, and human-friendly. I merged deep hardware control with UI empathy, delivering a platform that empowered non-technical operators while achieving technical excellence.