🏭 Manufacturing
Smart Factory Transformation for a Mid-Size Industrial Manufacturer
↓ 45% Downtime
ROI in 14 Months
The Challenge
A 500-employee manufacturing facility was losing an estimated $1.2M annually to unplanned machine stoppages. Maintenance was entirely reactive — faults were discovered only after production halted. No real-time visibility existed across the factory floor, and shift supervisors relied on paper-based logs and manual inspections.
Our Solution
Algorion deployed a comprehensive Industrial IoT network across 38 production machines, integrating vibration, temperature, and power-draw sensors. A predictive maintenance AI model was trained on 18 months of historical fault data. A real-time OEE dashboard was built on their existing SCADA infrastructure, with automated alerting to maintenance teams via mobile.
The Outcome
Within 6 months of go-live, unplanned stoppages dropped by 45%. The predictive model achieved 91% fault-prediction accuracy with an average 72-hour advance warning. Energy consumption fell 22% through load-scheduling optimisation. Full ROI was realised in 14 months.
45%
Downtime Reduction
91%
Fault Prediction Accuracy
22%
Energy Savings
14mo
Full ROI Achieved