A global industrial conglomerate
Reduction in unplanned downtime
Decrease in quality defects
Projected annual savings at scale
Challenge
Across 45 factories in 12 countries, fragmented manufacturing systems caused poor yield visibility, excessive downtime, and quality costs at 4.5% of revenue.
Approach
We designed and piloted a smart factory blueprint at three reference plants, deploying IoT sensor networks, a unified manufacturing execution system, and machine-learning-based predictive maintenance models. We built a center of excellence to scale the blueprint globally and trained over 2,000 plant managers and engineers on the new digital tools.
Impact
Pilot plants achieved a 45% reduction in unplanned downtime and a 60% decrease in quality defect rates. The blueprint was approved for rollout to all 45 facilities, with projected annual savings of $280 million at full scale.