Cutting factory downtime by a third with predictive AI
A manufacturer ran on spreadsheets and reactive maintenance. We unified operations in a modular ERP with IoT and predictive AI.
-31%
Downtime
-46%
Stockouts
-90%
Reporting time
Disconnected tools meant no real-time visibility, frequent unplanned downtime and costly stockouts across multiple plants.
- 1Built a modular ERP (inventory, production, quality) on Java + Kafka
- 2Streamed machine telemetry into real-time IoT dashboards
- 3Trained a predictive-maintenance model to flag failures early
- 4Automated reorder points to eliminate stockouts
- 5Rolled out plant by plant with on-site training
“For the first time we can see the whole operation in real time — and fix problems before they stop the line.”
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