Scalable real-time monitoring and reporting system for production lines using distributed databases

This paper presents an automated system for monitoring production lines, managing key indicators like production rate, rejection rate, and downtime. Integrated with a Manufacturing Execution System (MES), it collects essential data such as part numbers and production figures, enabling periodic queries and minute-by-minute chart updates. At the end of each shift, it generates automatic PDF reports. Built using a distributed database architecture with MS SQL Server, the system integrates production data, downtime, and rejection rates. Users manage settings and access through ASP.NET MVC, with ASP.NET Identity for authentication and authorization. Scalable and efficient, it supports adding new production lines without performance issues and has been implemented across multiple plants. Statistical tests revealed significant improvements in production (-1923.80), rejection (-210.87), and downtime (-2.87), with p-values < 0.001. Future enhancements include early detection rules for process failures, enabling preventive alerts to further improve quality and efficiency.