Manufacturer Reduces Unplanned Downtime by 47%
THE CHALLENGE
A discrete manufacturer was losing $2M annually to unplanned equipment failures. Their maintenance was entirely reactive with no visibility into equipment health.
OUR APPROACH
Implemented IoT sensors across critical equipment, built predictive maintenance models using machine learning, and integrated real-time dashboards with existing MES systems.
Tech Stack
Timeline
10 months
THE RESULTS
47% reduction in unplanned downtime in the first year
$940K annual savings from avoided unplanned failures
Maintenance labor efficiency improved by 30%
Spare parts inventory reduced by 22% through predictive ordering
"We went from guessing when things would break to knowing weeks in advance."
Plant Manager, Industrial Equipment Manufacturer
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