Success Story

The best visibility and latency in the production line.

BeijingWest Industries (BWI Group)

Production of suspensions, brakes | Production


Visualization of OPC UA data to show the current status of different machines, the solution should also work as a MES system.


Integration of Peakboard Boxes to the different stations in the company to visualize data in real-time


  • Agile planning thanks to real-time data
  • Fast implementation and easy integration of all the necessary data sources
  • Higher employee motivation

Time to value

One working day for the creation of the first dashboard and integration into the system

The customer

BWI Group.

BWI Group is a premier automotive parts supplier that designs and manufactures brake and suspension products for the global transportation market. What is now known as BWI Group began over 100 years ago and has grown to include 1,000 engineers, designers and technicians that produce engineering solutions for customers such as Ford, BMW, Honda, Volvo, Cadillac, Mini and Chevy.

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„From the first minute the employees loved Peakboard and the visualization. They are much more motivated because they see the daily goals and workload. More transparency in the whole company.“
Jordan Marlin, Manager Operational Technology, Industry 4.0 Engineering at BWI Group


Take the numbers to the people.

At BWI Group’s production facility in Greenfield, Indiana, management and employees had to wait 24 hours to analyze and discuss assembly-line output numbers from the previous day. This latency prevented the team from quickly identifying and responding to the inevitable production issues in an agile manner. According to Jordan Marlin, the Greenfield plant’s operational technical engineering manager,

“We needed a way to get real-time numbers out to our team, as soon as possible.”

BWI’s legacy business intelligence platform didn’t provide the crucial real-time updates that were needed, with cloud refresh latencies of eight minutes and local refresh latencies of 15 minutes. Further, this legacy platform provided rudimentary interactivity and required an expensive on-premises license. Compounding matters, dashboards in BWI’s existing Manufacturing Execution System (MES) were not flexible enough. Vital interactive inputs, such as number of shifts, shift duration, and breaks could not be integrated, making it impossible for BWI to have full visibility into its manufacturing processes.

“Management had no way of knowing the current status of the production lines”, continued Jordan.

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It only took minutes with Peakboard.

What BWI Group needed was a real-time visualization solution that was able to seamlessly connect and integrate with all its hardware and software platforms, from its legacy technology providers. BWI’s system architecture was typically complex on the production floor, with multiple machine controllers and programmable logic controllers (PLCs) upstreaming data to an OPC UA server. The resulting challenges included loading and integrating data from this highly fractured IT environment, in real-time, and doing so without the need of consultancy services.

BWI’s answer began with a trial of a single Peakboard Box. The trial required only minutes to load the data and deploy, with the benefits immediate.

“With these results, everybody wanted Peakboard on their station,” says Jordan Marlin.

Today, the Greenfield plant has 17 Peakboard Boxes in production use. Installed on every station of the suspension production line, Peakboard now provides fully integrated data visibility with real-time updates every ten seconds. These visualizations show key performance indicators such as overall equipment effectiveness (OEE), cycle times, and hourly production numbers, including good parts and rejected parts. Team effectiveness – daily shifts with the current week, best hour and best shift data – is also displayed.

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More, Better, Faster.

Peakboard enables BWI to drive bottom line impact by optimizing its manufacturing processes. Importantly, broad deployment of Peakboard Boxes has enabled BWI to gain visibility into its production line, and, crucially, to deliver that visibility from top to bottom across the organization. These insights were not possible under BWI’s existing legacy business intelligence platforms.

“Peakboard has enabled us to do real-time incentives,” says Jordan Marlin. “Going home early when we’ve achieved our production goals. Peakboard has been so well received by our operators. They love to see its display.”

Peakboard’s solution for BWI was both cost-effective and quick to deploy. By integrating and interpreting data from heterogeneous systems on a real-time basis, Peakboard has allowed BWI to eliminate friction from its processes, helping the company toward its goal of zero-error manufacturing.

“We want more!”

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Peakboard worldwide.

The success of the Peakboard solution at BWI is leading to aggressive expansion of its use within the company. This expansion includes additional Peakboard product functionality being deployed, including Advanced Charts, as well as expansion into new application areas and geographies. Because of the value shown by Peakboard on the manufacturing floor, BWI is now expanding the product’s use to its logistics operations in warehousing and trucking, as well as expanding Peakboard’s use to BWI’s facilities in Mexico.

“We’re seeing higher output and higher quality. We’re seeing better employee motivation. This was our big ‘Aha!’ moment.”

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“For me, digitization also means generating real added value from existing data. And that’s exactly what we are doing with Peakboard: We provide employees with the information they really need in their daily routine – in a simple manner and exactly where they are needed, whether in the office, in the factory hall or on the forklift.”

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“The effects have been consistently positive. The overall effectiveness of production has increased, and our planning is more accurate. Our processes have also been significantly accelerated thanks to the MES functions. Our teams are even more motivated than before, and they are really leaning into the friendly competition to achieve the goals.”

Mityo Dryankov, Director Maintenance, Innovations and Technology at Bon EOOD.


“We were able to set up the dashboard so that we could self-manage it: We downloaded the Peakboard Designer, chose the components to be displayed, and then configured and set up the Peakboard Box. This was a simple task due to our knowledge of automation structures. There was also a lot of learning by doing, which was fun. We were able to put the first implementations into live operation after just a week.”

Ralph Sagberger, Head of Organization & Production at Corratec


„With Peakboard, information is now quickly and transparently available right where it is needed.“

Sandra Schubert, Process Optimization at GBA Group

GBA Group

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“Only Peakboard met our requirements for standardized interfaces to various systems, especially SAP, as well as the visualization of shop-floor data in real-time and with no programming required.”

André Fimpel, Head of Lean Management at Helmut Fischer GmbH

Helmut Fischer GmbH

Helmut Fischer GmbH
“We like the easy usability of the Peakboard Designer and that complex designs can still be created with LUA. The excellent support from Peakboard and the speed with which new functions are implemented is clearly worthy of mention.”

Marc-Philip Stüttern, Head of IT at Joh. Clouth GmbH & Co. KG

Joh. Clouth GmbH & Co KG

Joh. Clouth GmbH & Co. KG
“By using Peakboard we have become faster and more precise in our processes. The newly gained transparency also reveals further potential for process optimization, which we will gradually exploit.”

Björn Mutschler, Head of Production at Johannes Giesser Messerfabrik GmbH

Johannes Giesser Messerfabrik GmbH

Johannes Giesser Messerfabrik GmbH
“With Peakboard, we have achieved efficiency through greater transparency. Employees can see at a glance right from their workplace what the current status is and can steer their work steps accordingly.”

Oliver Herz, Head of Application Development at MUNSCH-Group

Munsch Plastic Welding Technology

Munsch Plastic Welding Technology
„We needed a centralized display of current production data on an andon-board to take the next big step toward operational excellence. Employees should be able to see the status of their plant in real time: What is running on my machine right here, right now? The solution selected also had to be able to become the standard in our group to avoid having to work with a large number of different systems.“

Mario Pichler, Head of Automation at Pankl Racing Systems Inc.

Pankl Racing System AG

Pankl Racing Systems AG

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