Company
Large-Scale Steel Tube and Pipe Manufacturer
Workforce
Multiple high-speed production line teams
Time to Deploy
3 weeks to digitize core data; full predictive insights in 4 months
45% reduction in Mean Time To Repair (MTTR). $350,000 annualized savings from failure avoidance. 18% improvement in OEE on welding lines. 90% time saved on information search.
Our client operates multiple high-speed tube forming and welding lines, producing structural and distribution piping. Their operation's core reliance on high throughput meant any unplanned stoppage was disastrous. Despite having PLC systems and some basic sensor data, the crucial maintenance activity – work orders, failure history, diagnostic notes, and equipment specifications – was scattered across shared Excel spreadsheets and paper logbooks. Maintenance decisions were reactive, based on who last worked on a machine or who could find the right spreadsheet row. This system was slow, error-prone, and provided zero proactive insight.
The manual, spreadsheet-heavy environment created deep operational friction: diagnosis paralysis with technicians wasting time searching fragmented documents, zero proactivity as manual data couldn't be analyzed quickly enough to predict failures, inconsistent data quality from entry errors and forgotten updates, and reactive maintenance posture with no predictive capabilities.
Stop relying on slow, error-prone spreadsheets that hide critical insights.
