All Case Studies
Manufacturing
·
Digital Transformation
PureForm Manufacturing
Digital Factory Transformation
The Challenge
A precision manufacturing company with five plants operating on legacy systems. No real-time visibility into production performance. Quality issues were detected late, causing expensive rework and customer complaints.
Our Approach
We designed and implemented a digital factory program: IoT sensors on critical equipment, real-time production dashboards, predictive maintenance algorithms, and automated quality inspection. We started with one plant as a proof of concept before scaling.
Results
- 22% improvement in OEE across all plants
- Unplanned downtime reduced 45%
- Quality defect rate dropped from 2.8% to 0.9%
- Real-time visibility for plant managers and executives
- $8M annual savings from reduced rework and downtime