Smart Factory Enablement for a Indian Manufacturing Giant
Client Overview
Industry: Industrial Automation + Manufacturing
Size: €12 Billion Revenue | 70+ Plants Worldwide
Regions Served: EU, China, Mexico, India
Engagement Model: IoT + AI + Edge Computing
IBU’s Role: Smart Factory Blueprint, IoT Sensor Network, Predictive Maintenance AI
The Challenge: High Downtime, Low Line Efficiency
Machines were failing unpredictably. Maintenance was reactive, and factory managers lacked live insights. Manual reporting created a data lag.
Pain Points:
- 14% unplanned downtime
- Manual error logging in paper-based systems
- Energy usage inefficiency across plants
- No central data lake for operational intelligence
Why IBU? Manufacturing-Savvy Digital Execution
IBU blended:
- Edge AI capabilities
- Real-time dashboards with OPC-UA connectors
- Predictive maintenance algorithms trained on time-series data
The Solution: Connected, Self-Aware Factory Floors
Phase 1: IoT + Sensor Deployment
- Installed 1,500+ sensors across 12 pilot lines
- Connected machines to cloud via edge gateways
- Captured 25+ performance signals per unit
Phase 2: AI Model Integration
- Built predictive models for failure, quality drops, and energy spikes
- Triggered alerts to maintenance apps
- Created AI-driven OEE (Overall Equipment Effectiveness) dashboards
The Metrics: What We Delivered
Metric | Before IBU | After 8 Months |
Machine Downtime | 14% | 3.1% |
Maintenance Cost | €9.2M | €5.4M |
Energy Efficiency | 67% | 91% |
“It wasn’t just about sensors. It was about making our machines smart.”
