Um conglomerado industrial global
Redução de paradas não planejadas
Redução de defeitos de qualidade
Economia anual prevista em escala
Desafio
Em 45 fábricas de 12 países, sistemas fragmentados reduziam a visibilidade de rendimento, geravam paradas e elevavam o custo da qualidade a 4,5% da receita.
Abordagem
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.