Dayco × Signalo

Dayco, an international manufacturer of engine components and drivetrain systems, faced challenges at its Tychy plant related to machine efficiency, warehouse management, frequent downtime and limited process visibility.

Key challenges included frequent downtime, lack of real-time data and manual resource management. Dayco needed an automated, scalable system to improve operational transparency.

The company experienced difficulties in monitoring inventory levels, controlling spare parts, and the lack of demand forecasting caused delays.

The absence of automatic alerts and a centralized communication system led to secondary downtime, delayed maintenance response and rising operational costs.

The partnership with Signalo involved the implementation of CMMS, ANDON 4.0, machine monitoring and intralogistics automation using FORKFLEET. Below is the full transformation of Dayco’s processes — preserving all delivered scope.

Better decisions through performance monitoring

A deeper understanding of processes began with machine instrumentation. CMMS and Andon 4.0 enabled automated performance monitoring and identification of improvement areas.

Machine monitoring and rapid issue detection

CMMS enabled tracking KPIs such as machine performance, failure rates and downtime. Real-time monitoring allowed fast identification of issues impacting results.

Machine instrumentation and maintenance optimization

Data analysis from CMMS identified machines requiring frequent service, those with lowest efficiency and those performing most reliably.

Automatic alerts minimizing failure risk

ANDON 4.0 instantly reported failures and routed notifications to the right teams, reducing downtime and preventing more serious machine damage.

Predictive asset and spare parts management

CMMS enabled forecasting service needs and planning spare parts purchases, eliminating downtime caused by missing components.

Accurate inventory tracking

CMMS automatically monitored inventory levels, supported spare part lifecycle management and accelerated response to shortages.

Faster response to inventory shortages

The system tracked part movement and predicted consumption, improving purchasing planning and eliminating excess inventory.

Real-time response

ANDON 4.0 instantly reported spare part shortages, directing information to the appropriate teams.

Logistics without unnecessary delays

FORKFLEET increased warehouse efficiency by allowing forklift requests with a single click.

“Uber” for forklifts

The system works like a ride-hailing app — operators “request” forklifts where needed, eliminating empty runs.

Fleet efficiency

FORKFLEET analyzed routes and operator workloads, identifying bottlenecks and increasing logistics throughput.

CMMS as the process monitoring hub

The system tracked all activities: failure reports, spare part orders and logistics tasks, enabling trend analysis.

Delay analysis and operational improvement

CMMS data allowed identification of delays and implementation of corrective actions.

Automatic alerts = immediate action

ANDON 4.0 shortened response times through instant notifications.

Continuous improvement through response time analysis

Dayco used data to continuously optimize operations and increase productivity.

Manufacturing IT systems — real results

Automatic reporting, instant alerts and faster responses shortened repair times and reduced failure frequency.

Better work organization, optimized material flow and logistics automation improved overall plant efficiency.

CMMS and Andon 4.0 eliminated part shortages, accelerated purchasing and reduced inventory costs.

The synergy of CMMS, ANDON 4.0 and FORKFLEET enabled full process control and cost reduction across the entire plant.

Dayco is an example of a company that, through Industry 4.0 technologies, achieved measurable operational and financial benefits.