Company
Mid-sized Plastics Manufacturer
Workforce
Multiple plant operations teams
Time to Deploy
4 weeks for data unification; 12 weeks for sustained 22% reduction
22% reduction in unplanned downtime. 4x faster incident triage. Consolidated data from 3 systems. Repeat failures on critical assets reduced by 35%.
In the high-stakes world of plastics manufacturing, where margins are tight and production runs are continuous, efficiency is non-negotiable. Our client, a manufacturer of complex automotive and consumer packaging plastics, operated two large-scale plants. Despite modern machinery, including multi-axis injection molding and high-speed extrusion lines, their maintenance teams were constantly fighting fires. The core issue was data fragmentation. Critical maintenance data resided in scattered silos: Plant 1 used a legacy, on-premise CMMS. Plant 2 used a simple spreadsheet and paper-based work order system. All Plants had real-time sensor data from PLCs/SCADA systems logged locally but never correlated with equipment's historical maintenance record.
This lack of a single source of truth meant every troubleshooting process started with a time-consuming search across systems, emails, and physical binders. Maintenance decisions were reactive, based on incomplete history, resulting in high rates of repeat failures and directly impacting overall equipment effectiveness (OEE).
Is your organization still struggling with scattered spreadsheets and legacy systems?
