Real Results. Real Factories.

Impact Stories

See how manufacturers across India have transformed quality, traceability, and energy efficiency with ZillionEdge Industrial IoT solutions.

6+
Industries
50+
Deployments
5
Offices in India
5+
Years Experience
Vision SolutionsAutomotive

94% Reduction in Defect Escape Rate at Tier-1 Auto Supplier

Challenge

A leading Tier-1 automotive components supplier in Pune was relying on manual visual inspection for engine mounting brackets, resulting in 3–5% escape rate and frequent customer complaints.

Solution

Deployed ZillionEdge AI-powered vision inspection system with 4-camera setup on the production line, integrating with existing PLC for automatic rejection of non-conforming parts.

Key Results
94%
Reduction in defect escapes
6×
Faster inspection cycle
₹28L
Annual savings on rework
Vision InspectionAutomotiveQuality Control
TraceabilityPharmaceuticals

Full Serialization Compliance for Pharma Export Markets

Challenge

A major pharmaceutical manufacturer in Hyderabad needed to achieve end-to-end serialization for export to regulated markets (EU FMD, US DSCSA), with a tight compliance deadline.

Solution

Implemented RFID-based traceability system across 3 packaging lines with cloud-connected aggregation, enabling unit-level tracking from production to dispatch.

Key Results
100%
Regulatory compliance achieved
3 lines
Deployed in 8 weeks
0
Compliance failures post-deployment
RFID TraceabilityPharmaSerialization
Vision SolutionsHeavy Engineering

Automated Weld Quality Inspection at Heavy Engineering Company

Challenge

A heavy engineering company in Chennai was manually inspecting weld quality on large structural assemblies — a slow, inconsistent process that created bottlenecks and missed sub-surface defects.

Solution

Deployed ZillionEdge vision system with high-resolution line-scan cameras and AI-based defect classification, integrated with the MES for real-time quality reporting.

Key Results
80%
Reduction in inspection time
99.1%
Defect detection accuracy
4 months
ROI payback period
Vision InspectionHeavy EngineeringWeld Quality
TraceabilityFMCG

Batch Traceability Cuts Recall Investigation from Days to Minutes

Challenge

An FMCG manufacturer in Manesar had no end-to-end batch visibility across their 5-line facility. A product recall took 3–4 days to investigate root cause, risking brand reputation.

Solution

Deployed QR code-based traceability across all production and packaging lines, linking raw material lots to finished goods with a centralized traceability dashboard.

Key Results
< 8 min
Recall investigation time
5 lines
Full traceability coverage
100%
Batch genealogy visibility
Barcode / QRFMCGBatch Traceability
Energy ManagementProcess Industry

22% Energy Cost Reduction at Process Manufacturing Plant

Challenge

A chemical process plant in Pune had no visibility into machine-level energy consumption. Energy bills were consistently rising, with no way to identify wasteful equipment or idle-running machines.

Solution

Installed ZillionEdge IoT energy meters on 40+ machines with real-time monitoring dashboard, automated alerts for anomalies, and shift-wise energy reports for plant managers.

Key Results
22%
Reduction in energy costs
40+
Machines monitored
< 6 mo
Full ROI payback
Energy ManagementProcess IndustryIoT Monitoring
Vision SolutionsEngineering

99.2% Inspection Accuracy on Precision Machined Parts

Challenge

A precision engineering company in Chandigarh supplying to aerospace and defence OEMs needed to replace manual gauging with automated dimensional inspection to meet tighter tolerances.

Solution

Implemented ZillionEdge multi-axis vision measurement system with submicron accuracy, capable of inspecting 12 critical dimensions per part in under 3 seconds.

Key Results
99.2%
Inspection accuracy
3 sec
Per-part cycle time
60%
Labour cost reduction
Vision InspectionEngineeringDimensional Gauging

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