Live Deployments
Businesses Running on Airwix
Real-world manufacturing and engineering operations running on unified cloud infrastructure. See how they automated compliance, eliminated inventory leaks, and digitized shop floors.
ACTUAL SHOTPrecision Fastener Manufacturer
The Challenge
Operating across two cold forging facilities, the manufacturer struggled with high tooling setup times and high metal scrap rates during machine caliber changes. Outdated paper-based machine routing logs led to high human error rates during setups.
The Solution & Impact
Airwix implemented digital machine routing and real-time tooling setup logs. Setup parameters are now synced directly to floor tablets. Correct setup validations are mandatory on the system before starting a forging batch, which eliminated caliber errors, reduced tool change times by 35%, and saved $90,000 in material scrap.
"Airwix digitized our tooling setups and forging logs. Setup scrap fell by 45% in the first two weeks."— Production Head
ACTUAL SHOTPrecision Auto Parts Manufacturer
The Challenge
As an exporter to 15+ global automotive OEMs across 3 plants, tracking CNC tool wear was a major pain point. Machine operators logged downtime on paper sheets, leading to delayed corrective action and high tooling replacement costs.
The Solution & Impact
Airwix established live OEE tracking and machine wear logs. Floor managers receive alerts for preventive tooling changes, reducing downtime by 40% and cutting tooling replacement waste by $140,000. Overall plant OEE increased from 55% to 82%.
"Airwix gave our floor managers real-time visibility. Tooling downtime dropped to zero on week two."— VP of Operations
ACTUAL SHOTIndustrial Valve Manufacturer
The Challenge
Supplying valves to the highly regulated oil & gas industry requires ironclad heat-code traceability for cast steel parts. With 18 inventory locations and external casting sub-contractors, tracking material certs on paper caused major dispatch blockages.
The Solution & Impact
Airwix established serialized tracking linked to batch material certificates. Heat code data is validated automatically at the CNC machining and hydrostatic pressure test stages, completely eliminating paperwork delays and ensuring 100% compliant shipments.
"We needed heat-code traceability for every valve. Airwix automated it from raw casting to final dispatch."— Quality Assurance Head
ACTUAL SHOTWeight Calculator Machine Manufacturer
The Challenge
A major supplier of industrial load-cells and electronic scales struggled with bottlenecks at the testing and calibration benches. Logging calibration values manually on paper certificates was prone to transcription errors, risking compliance failures.
The Solution & Impact
Airwix established direct cloud synchronization for digital calibration logs. Scale test readings are recorded automatically on shop floor terminals, reducing QA check times by 40% and completely eliminating manual entry errors for 100% compliance.
"Calibration data is now synced directly to our quality records. Airwix eliminated manual entry errors on our testing benches."— QA Director
ACTUAL SHOTHeavy Gearbox Manufacturer
The Challenge
Manufacturing high-torque custom gearboxes involves complex, multi-level Bills of Materials (BOMs). Design engineers frequently issued drawing revisions, but floor workers often used outdated paper versions, leading to parts machined to wrong sizes and high scrap rates.
The Solution & Impact
Airwix CAD integrations synchronized design files and BOM revisions automatically. Shop floor tablets show the latest engineering specs instantly. Outdated revisions are flagged on machine job cards, resulting in an 18% scrap rate drop within the first month.
"With 1,200 active BOMs, engineering changes used to cause massive scrap. Airwix syncs design revisions instantly."— Engineering Director
ACTUAL SHOTPower Transformer Manufacturer
The Challenge
As a state utility supplier with 1.2M kVA annual capacity, managing copper coil winding WIP on paper cards was highly inefficient. High value inventories were tied up on the shop floor without clear bottleneck visibility.
The Solution & Impact
Airwix implemented real-time barcode tracking for winding cycles and core assemblies. Winding delays are automatically highlighted, cutting average WIP cycle time by 24% and freeing up over $300,000 in working capital.
"Tracking copper winding WIP on paper was a nightmare. Airwix digital job cards freed up our working capital."— Plant Manager
ACTUAL SHOTSpecialty Chemicals Manufacturer
The Challenge
Operating complex batch process reactors, the manufacturer struggled with batch inconsistency due to manual recipe calculation and weighing logs. This resulted in high material wastage and product batch QA failures.
The Solution & Impact
Airwix established digitized recipe formulations linked to automatic weighing scale sensors. The system prevents batch reactor operations if material proportions deviate, guaranteeing 100% batch recipe consistency and saving 22% in raw chemical material waste.
"Airwix digitized our batch recipes. Weighing-scale integrations ensure perfect batch proportions, cutting raw material waste by 22%."— Operations Lead
ACTUAL SHOTFMCG Products Manufacturer
The Challenge
With multiple high-speed bottling and packaging conveyor lines running 24/7, tracking batch expiration dates and shipping pallets manually was highly error-prone, leading to shelf-life tracking failures and dispatch blocks.
The Solution & Impact
Airwix automated QR-based pallet serialization. Ingredient batches are scanned and linked directly to outer box labels during primary packaging. Dispatch managers scan pallets on mobile scanners to verify expiry profiles, eliminating manual mistakes and cutting shipping errors by 95%.
"Tracing product batches from ingredients to final shipping pallet is now fully automated. Expiry tracking errors fell to zero."— Supply Chain Head
ACTUAL SHOTIndustrial Boiler Manufacturer
The Challenge
Operating across two sprawling fabrication yards with over 800 employees, the company relied on paper blueprints and manual logs to track welding quality. Lack of audit trials for high-pressure welds led to high inspection failure rates and scrap metal wastage.
The Solution & Impact
Airwix digitized the shop floor, generating QR-coded digital job cards for every weld. Inspectors log hydrostatic and radiographic check results directly on mobile tablets. Material scrap logs are updated instantly, saving $220,000 in steel waste within the first quarter.
"Airwix digitized our entire quality inspection checklist for high-pressure welds. Traceability is now instant."— Operations Director
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