Updated: August 04, 2025
An automotive plant outside Gurugram lost connectivity across two assembly lines last quarter. Not for long - just 27 minutes. But in that time, six AGVs missed their calibration cycles, telemetry logs failed to upload to the MES, and the ERP dashboard froze on dispatch schedules.
A single switch rebooted slower than expected. It had no failover. Line managers flagged the issue. The CIO ran diagnostics. The vendor shared logs. None of it changed what the COO reported to the board: the day’s output dropped by 83 units.
You run a manufacturing operation, not a server farm. But your IT backbone now decides whether your dispatches hit timelines, whether your quality audits close cleanly, whether your analytics stay real-time.
Several auto plants in Gurugram were networked for voice, email, and security cameras. Today, they’re expected to support RFID readers, automated conveyors, MES dashboards, smart scanners, and analytics workloads, all on the same architecture. Many don’t cope well.
During recent technical evaluations across six automotive sites in Manesar, Bawal, and Dharuhera, Proactive found:
These aren’t exceptions. They are patterns.
According to ARC Advisory Group, auto OEMs can lose between $22,000 and $50,000 per minute of unplanned line stoppage. This comes from contract penalties, schedule disruption, and rework.
Multiply that by 27 minutes. Now factor in the number of Gurugram plants producing brake systems, axles, fasteners, and seat assemblies for Tier-1 contracts. A delay at one plant doesn’t just halt operations there. It disrupts delivery chains downstream.
Every plant IT leader knows this. Yet many still rely on flat-layer switching, shared SSIDs, and untested DR plans.
You don’t need a full overhaul. But you do need clarity on these six questions:
If any of these is a “no,” your network isn’t production-grade.
A factory-ready network has a defined reference:
Without these, any upgrade to smart systems or MES integration risks introducing more instability than insight.
Your clients demand more than dispatch volume. They require SLA proof, uptime metrics, traceability trails, and ISO/TS audit data logs.
Failover protocols, VLAN logs, and access logs are now requested during Tier-1 client reviews. If your Wi-Fi or switch architecture cannot isolate production events from user-originated faults, you risk non-compliance.
That risk translates to lost contracts. Not just downtime.
In one assessment, a single guest device connected to an open SSID in a Dharuhera plant triggered a MAC flood event. The entire MES network dropped for 17 seconds. No data breach occurred, but production paused.
One guest phone. One open VLAN. No containment.
You know the cost of downtime: up to 40 lakh per hour. But what is the cost of rework, investigations, compliance flags, and internal loss of confidence?
Proactive’s average re-architecture for a 2-line floor with 1 NOC hub costs less than one penalty incident in a year. And once done, it prevents a dozen more.
Your current network might be holding, but what happens when:
Each of these breaks something hidden in your network unless already designed for it.
A Tier-1 auto component manufacturer in IMT Manesar was facing frequent MES lags and delayed batch transfers to ERP. Proactive redesigned their floor networks: upgraded PoE switches, new VLAN architecture, role-based segmentation, and dual-WAN routing with LTE fallback.
We completed it in two phases, with zero disruption. MES sync errors fell by 93 percent. Average Wi-Fi roaming handoff time dropped from 4.7 seconds to under 1.2 seconds.
Their IT head never went back to answering 6 a.m. outage calls.
OEM vendors offer architecture blueprints. Proactive starts with operational maps. We walk your site. We document all your switch routes, your controller config, your Wi-Fi coverage holes, and your incident logs.
Then we show you where failure will hit first.
This isn’t a pitch. It’s a risk report. If you plan to expand capacity, integrate with a global MES, or meet stricter SLA contracts, this check is not optional.
Proactive helps auto manufacturers design plant networks that don’t freeze when one device fails or one operator roams across zones. Our Gurugram deployments span EV assembly, drivetrain components, and critical tiered suppliers.
We speak the language of uptime. We speak factory.
Let us walk your plant. You’ll see why 9 out of 10 plants we assess go on to redesign their backbone within 60 days.
