Manufacturing IoT & Predictive Maintenance
Client
Global Manufacturing Conglomerate
Overview
A global manufacturer operating 50+ facilities was experiencing frequent equipment failures causing production downtime and maintenance costs. We implemented IoT sensors and ML-based predictive maintenance.
The Challenge
Our Solution
Tech Stack
Key Results
downtime
73% reduction in unplanned downtime
maintenance Costs
45% reduction in maintenance expenses
production Efficiency
38% improvement in OEE
maintenance Accuracy
91% accuracy in failure prediction
cost Savings
$8.5M annually in avoided downtime
Predictive maintenance prevents critical failures before they occur
Unplanned downtime reduced from 5% to 1.3% of operational time
Maintenance costs optimized through predictive scheduling
Cross-facility insights enable best practice sharing
ROI achieved in less than 14 months