Manufacturer Reduces Downtime by 73% with Predictive Maintenance AI
Key Results
The Challenge
Unplanned equipment downtime was costing the manufacturer $18M annually. Maintenance was reactive, leading to production delays, missed deliveries, and customer penalties. Equipment utilization averaged only 67% due to unexpected failures.
The Solution
Stratafy's assessment revealed the company was at 51% AI readiness, with significant gaps in IoT infrastructure and data engineering capabilities. Our roadmap guided them through: (1) Installing 15,000+ IoT sensors across facilities, (2) Building centralized data lake for sensor data, (3) Developing predictive maintenance ML models, (4) Creating maintenance optimization dashboard for plant managers.
Technologies & Approaches
The Results
Decreased unplanned downtime from 420 to 113 hours/year
Improved from 67% to 89% overall equipment effectiveness
Reduced maintenance spending by $7.4M annually
Increased production capacity without new equipment
Stratafy's assessment helped us understand that AI readiness isn't just about algorithms—it's about data infrastructure, organizational change, and governance. Their phased roadmap made a $22M AI investment feel manageable and low-risk. We're now seeing ROI we never imagined.