Real-Time Production Intelligence for a Leading Marine Automotive Manufacturer

Setting the Context

The client is a prominent U.S.-based manufacturer of automotive parts for marine vessels such as water boats, trawlers, and yachts. As demand increased, the client recognized limitations in their existing siloed systems—particularly around real-time production cost tracking, inventory control, and visibility across multiple factory locations. They aimed to digitize and unify operations to enable smarter decision-making and operational agility.

Project Goals

To support the client’s digital transformation journey, we were engaged to rearchitect their operations platform into an intelligent, integrated solution focused on real-time insights and streamlined factory operations.

• Build a centralized system for real-time production and inventory tracking across multiple factories.
• Develop an admin dashboard to monitor resource utilization and optimize cost structures dynamically.
• Integrate with JD Edwards ERP for unified data synchronization and business continuity.

The GenAquarius Approach

Platform Re-architecture & Real-time Processing:

• Designed a modular platform using Java Spring Boot microservices architecture deployed on Kubernetes (AKS).
• Integrated Apache Kafka to handle real-time event streams from factory-floor sensors and production systems.

Inventory and Cost Intelligence System:

• Developed dynamic costing modules that factor in raw material prices, labor costs, and operational overhead.
• Enabled predictive inventory management using Elasticsearch for fast data retrieval and trend analysis.

Admin Dashboard & Analytics:

• Built an executive dashboard using Angular with role-based access to monitor KPIs, production targets, and resource efficiency.
• Embedded Power BI reports for live tracking of inventory, order backlog, and cost leakage across regions.

ERP Integration:

• Integrated with JD Edwards ERP via RESTful APIs and messaging queues to ensure seamless synchronization of procurement, finance, and logistics data.

Multilingual Enablement & Internationalization:

• Implemented multilingual support (English, Dutch, French) using ngx-translate in frontend and resource bundles in backend.

DevOps & Compliance:

• CI/CD pipelines established via Jenkins and GitHub Actions, with automated testing using JUnit and Cypress.
• Ensured data compliance through encrypted transmission and role-based access controls.

Business Impact

• 15% increase in overall profitability due to smarter costing and resource visibility.
• 10–15% production uplift through proactive capacity planning and minimized stockouts.
• Enhanced cross-factory visibility, enabling regional managers to respond faster to demand and supply shifts.
• Introduced weekly/monthly offers and customer loyalty programs backed by real-time data insights.
• Improved decision-making via real-time dashboards and alerts on production delays or cost overruns.
• Fully internationalized platform enabled smoother expansion into Europe.

Technology Stack