Clients:

• Président Cheese Tunisia

• Tunisie Transformateurs

Industry:

Food & Dairy Manufacturing / Industrial Transformation

Service Provided:

Development of a highly secure, AI-enhanced web application for automation, monitoring, and optimization of complex manufacturing processes.

Technologies Used:

• Backend: Node.js, NestJS, PostgreSQL, Redis

• Frontend: Angular 16, WebSockets, Highcharts.js

• Security: AES-256 encryption, JWT, OAuth2, Role-Based Access Control (RBAC), IP Whitelisting

• DevOps: Docker, Kubernetes, GitHub Actions, Nginx reverse proxy

• Machine Communication: OPC-UA integration for IoT/PLC interfaces

• AI Layer: Python microservices (predictive maintenance, anomaly detection)

• Monitoring: Grafana, Prometheus

Project Overview

Président Cheese and Tunisie Transformateur, both leaders in their respective manufacturing sectors, needed an intelligent and secure platform to digitize, centralize, and automate their production workflows, machine monitoring, and quality control pipelines.

Their requirements demanded a next-gen solution that goes beyond traditional dashboards — one that could interact in real-time with factory machines, reduce human intervention, and offer predictive intelligence for system optimization and maintenance forecasting.

Challenges & Solutions

✅ 1. Real-Time Machine Data Integration

• Connected the web platform to SCADA systems and PLC controllers using OPC-UA protocol to extract live machine data.

• Created real-time dashboards that visualize temperature, pressure, machine speed, production output, and defect rates.

✅ 2. Intelligent Workflow Automation

• Developed custom workflows to automatically trigger alerts, halt production lines, or redirect batch processing based on anomalies or product specifications.

• Included a drag-and-drop workflow editor for operators to reconfigure manufacturing logic on the fly.

✅ 3. Predictive Maintenance with AI

• Used time-series analysis and anomaly detection algorithms to predict machinery breakdowns.

• Trained models on historical data to forecast maintenance schedules and reduce unplanned downtimes by over 40%.

✅ 4. High-Security Access & Auditing

• Integrated multi-level access control for engineers, operators, QA teams, and management.

• Applied AES-256 encryption, enforced IP whitelisting, and deployed OAuth2 login with 2FA for all critical modules.

• Logged every user action via a tamper-proof audit trail.

✅ 5. Seamless UI/UX for Industrial Environments

• Designed a UI that works well in touchscreen, kiosk-based factory terminals.

• Responsive interface with dark mode for control rooms and offline mode for areas with limited connectivity.

Impact & Results

📉 Reduced Operational Downtime by 45% through predictive maintenance.
📈 Improved Production Efficiency by automating low-level tasks and alerts.
🔐 Enterprise-Grade Security, ensuring compliance with internal and external audit requirements.
🧠 Smarter Decision Making through AI-based dashboards and performance forecasting.
📊 Real-Time KPI Tracking, customized by role and production unit.