Un conglomerado industrial global
Reducción de paradas no planificadas
Reducción de defectos de calidad
Ahorros anuales previstos al escalar
Desafío
En 45 plantas de 12 países los sistemas fragmentados restaban visibilidad de rendimiento, generaban paradas y elevaban el coste de calidad al 4,5% de los ingresos.
Enfoque
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.
Impacto
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.