Manufacturing Digital Transformation
How we helped a mid-size manufacturer cut production downtime by 40% in 6 months.
Our client was a 300-person manufacturing company struggling with legacy systems, manual reporting, and reactive maintenance culture.
The Challenge
Production downtime was costing the company €2M annually. Data was siloed and operational decisions were made on gut instinct rather than facts.
Our Approach
We conducted a 4-week diagnostic, mapped the value stream, identified the top 5 root causes of downtime, and designed a phased transformation roadmap.
Results
- 40% reduction in unplanned downtime
- 25% improvement in OEE
- Real-time production dashboard deployed in 8 weeks
- Full ROI achieved within 11 months