Manufacturing
$62M in Prevented Downtime Across 12 Facilities
-77%
unplanned downtime ($62M saved)
+42%
maintenance productivity
+23%
equipment lifespan extension
340%
project ROI in year one
Challenge
A global industrial manufacturer was suffering $80M/year in unplanned downtime across 12 production facilities. No predictive capability existed - machines broke and teams reacted.
Solution
We deployed an end-to-end IoT-to-AI pipeline across 1,200+ machines. LSTM-based time-series models trained on 18 months of sensor telemetry, predicting failures 7-14 days in advance. Integrated with SAP ERP for automatic maintenance work order generation.
Technologies Applied
LSTM NetworksApache KafkaTime-series Anomaly DetectionSAP IntegrationReal-time Alerting
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