01
Client Profile & Background
A large automotive parts manufacturer operating a 50,000 sqm factory in Bekasi, Indonesia, with over 2,000 employees across three shifts. The facility includes assembly lines, warehouses, and R&D labs. The company relies heavily on wireless connectivity for production line terminals, handheld scanners, and AGVs. Their existing network consisted of 60 legacy access points from a consumer-grade vendor, deployed over five years ago.
The IT team managed a mix of unmanaged switches and a flat network topology, leading to frequent broadcast storms and security vulnerabilities. The company was experiencing a 15% annual growth in connected devices, straining the aging infrastructure. They needed a scalable, high-density solution that could support future IoT expansion and comply with industry standards for data security.
02
Technical Challenge
The primary challenge was severe co-channel interference and signal degradation in the production floor due to metal racks and moving machinery. The legacy access points could not handle more than 20 concurrent clients per radio, causing frequent disconnections for handheld scanners, which resulted in a 12% downtime in warehouse operations. Additionally, the AGVs relied on a separate Wi-Fi network that experienced intermittent roaming delays of up to 5 seconds, causing collisions and production line stops.
A site survey revealed that the existing access points operated on 2.4 GHz only, with no support for 5 GHz or band steering. The network experienced a 30% packet loss during peak hours, and the average throughput per client was below 10 Mbps. The IT team had no centralized management, making troubleshooting and firmware updates manual and time-consuming. The challenge was to design a network that could support 500+ concurrent devices with seamless roaming under 50 ms and throughput of at least 100 Mbps per client for video inspection systems.
03
Implemented Solution
Intilogy designed and deployed a high-density WiFi 6 solution using Ruijie RG-AP840-I access points, which support OFDMA and MU-MIMO for efficient spectrum utilization. A total of 120 access points were installed, with 80 on the production floor and 40 in the warehouse and office areas. The deployment included a three-radio design (2.4 GHz, 5 GHz, and dedicated scanning radio) to eliminate interference and provide seamless roaming.
The network was segmented using VLANs and 802.1X authentication, integrated with the existing Active Directory. A networking upgrade included Cisco Catalyst 9300 switches for PoE+ and a Fortinet firewall for security. The solution also incorporated a cloud-based management platform, allowing the IT team to monitor performance and push updates remotely. For the AGVs, a dedicated SSID with fast roaming (802.11r) was configured, achieving sub-30 ms handoffs.
04
Results & ROI
Post-deployment, the factory experienced a 40% increase in overall network throughput, with average client speeds exceeding 200 Mbps. The warehouse scanner downtime dropped from 12% to under 1%, directly improving order fulfillment accuracy by 15%. AGV roaming delays were reduced from 5 seconds to 20 ms, eliminating production line stops and increasing overall equipment effectiveness (OEE) by 8%.
The centralized management reduced troubleshooting time by 70%, and the IT team could now proactively address issues. The solution paid for itself within 18 months through increased productivity and reduced downtime. Additionally, the network is now ready for future IoT expansion, with capacity to support up to 2,000 concurrent devices. The manufacturer also achieved compliance with ISO 27001 for information security, leveraging the cybersecurity features of the Fortinet firewall.
