Глобальный промышленный конгломерат
Сокращение незапланированных простоев
Снижение дефектов
Экономия в год при масштабировании
Задача
На 45 заводах в 12 странах разрозненные производственные системы лишали видимости выхода, увеличивали простои и поднимали стоимость качества до 4,5% выручки.
Подход
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.
Эффект
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.