CASE STUDY

From downtime to design flow: Reengineering operational efficiency in heavy manufacturing

Manufacturing & MachineryProcess Intelligence & Optimization

IMPACT SUMMARY

68%

Uptime Increase

Predictive routing reduced unplanned maintenance.

1.3x

Process Throughput

Throughput gains across assembly and packaging lines.

$3.1M

Annual Cost Savings

Efficiency-led savings across labor, energy, and parts.

+4K

Manual Work Hours Eliminated

Repetitive tasks automated across planning and QA

Project Snapshot

A global manufacturer of construction-grade compressors struggled with operational inconsistencies across its European plants. Process documentation was outdated, cross-team handoffs were inconsistent, and legacy tools obscured real performance metrics. Downtime diagnoses took weeks, and continuous improvement efforts stalled. Leadership needed clarity on how work actually got done—and a roadmap to run leaner, faster, and smarter.

Our Solution

We deployed AI-powered process intelligence to reconstruct real operations from system logs, ERP data, and floor-level workflows. Our agents revealed bottlenecks, redundant steps, and noncompliant workarounds across plants. In collaboration with ops leaders, we redesigned high-friction processes and introduced targeted automation for QA tracking, job routing, and maintenance planning. The result: a streamlined operation that runs on insight, not guesswork.

SERVICE MIX

Process Mapping & AnalysisWorkflow RedesignAutomation ImplementationOperational Change Strategy

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