Real-Time Equipment Visibility for a Global Medical Manufacturer
Partnering with a global medical accessories manufacturer, OnPoint Insights transformed a completely paper-based machine inspection process into a connected digital equipment and asset performance solution.
Built using Microsoft Power Platform, the solution digitized machine health inspections, streamlined defect management, automated safety notifications, and created analytics-ready operational data.
The result was a safer, faster, and more traceable inspection process — giving operations teams greater visibility into machine health across production lines.
Medical Manufacturing & Industrial Operations
44 Weeks
- Low-Code Application Development
- Equipment Inspection Digitization
- Defect Management Automation
- Safety Notification Automation
- Barcode Scanner Integration
- Master Data Management
- Operational Analytics
- Power BI Dashboard Development
The Challenge
A global medical accessories manufacturer relied entirely on physical paper records to monitor the health and operational status of production-line equipment. Maintenance teams manually moved across production lines and stations, inspected machines, and recorded results on paper forms. With no centralized digital system, inspection history, defects, corrective actions, and machine-health trends were difficult to track.
Paper-Based Machine Inspections
Machine health checks were recorded manually, leaving no centralized digital history for identifying recurring issues or equipment trends.
Limited Defect Traceability
Defects could be identified during inspections, but there was no structured process to log, classify, assign, and track them through resolution.
Delayed Safety Communication
Safety-critical issues relied heavily on manual communication, limiting supervisors’ ability to respond immediately.
Limited Operational Visibility
With inspection data stored on paper, leadership lacked the structured data needed to analyze machine health, maintenance frequency, and defect patterns.
Fragmented Corrective Actions
Assigning tasks and tracking ownership was inconsistent, making it difficult to establish accountability for defect resolution.
Our Solution
OnPoint Insights designed and delivered a fully digital Equipment & Asset Performance System using Microsoft Power Platform.
The solution connects machine inspections, defect management, automated notifications, asset identification, master data, and operational analytics within one scalable platform.
Built a responsive Power Apps solution for mobile, tablet, and desktop with role-based access to assigned production lines and stations.
Replaced paper forms with dynamic digital checklists that allow operators to inspect machines and raise defects with supporting details and images.
Created a structured workflow to review, assign, track, and close defects with complete traceability from identification to resolution.
Built an Admin Console that enables business users to manage users, lines, stations, machines, and checklist configurations without IT dependency.
Centralized inspection and defect data in SQL Server while securely storing supporting defect images in Azure Blob Storage.
Integrated Zebra barcode scanners to accurately identify machines and link every inspection and defect record to the correct asset.
Used Power Automate to instantly alert relevant stakeholders about defects, unresolved safety issues, and critical inspection events.
Results & Impact
The digital platform replaced fragmented paper-based processes with a centralized, traceable equipment inspection ecosystem.
100% Digital Inspection Process
Machine health inspections moved from physical paperwork to a fully digital workflow.
Faster Defect Identification
Structured digital reporting enabled defects to be identified and acted upon significantly faster.
Real-Time Safety Visibility
Automated notifications help ensure critical equipment and safety issues reach relevant personnel immediately.
Complete Inspection History
Every machine inspection now creates a searchable digital record, giving operations teams greater traceability across machines, stations, and production lines.
Analytics-Ready Operations
Centralized data enables Power BI reporting on machine health trends, defect frequency, maintenance activity, and other operational indicators.
Improved Accountability
Defect ownership and corrective actions can be assigned and tracked through a structured workflow from identification to closure.
Explore Other Case Studies
Next Case Study
Digitizing Continuous Improvement for a Global Medical Manufacturer
Enhancing Financial Insights for a Leading Philanthropic Fund
Enhancing Legal Data Insights for Smarter Judiciary Decisions
Collaborate with us
We're here to answer your questions and help you find the right solution.
"*" indicates required fields