Predictive Maintenance-Driven ERP for a Global Machinery Manufacturer
Client Overview
A large-scale industrial machinery manufacturer serving the construction, mining, and agriculture sectors. The company operates three manufacturing plants, supports 1,200+ B2B clients globally, and generates over USD 350 million in annual revenue.
The Challenge
As operations expanded, disconnected systems and reactive processes began impacting performance.
- Reactive maintenance cycles caused ~12 hours of unplanned downtime per month, resulting in USD 1.8M annual losses
- Manual order tracking across 1,200+ clients led to fulfillment delays and errors
- Supplier inefficiencies, including inconsistent pricing and delayed deliveries, reduced procurement reliability
- Siloed legacy systems prevented cross-plant visibility and slowed decision-making
The manufacturer needed a single ERP platform capable of unifying maintenance, orders, suppliers, and plant operations-while enabling predictive, data-driven decisions.
Our Solution
Predictive Maintenance Intelligence
IoT sensor integration to monitor equipment health and predict failures 10-14 days in advance, enabling preventive maintenance and reducing breakdowns.
Centralized Order Management
Real-time order tracking, automated scheduling, and dispatch notifications to improve fulfillment accuracy and customer reliability.
Supplier Control & Procurement
Unified supplier database with performance scoring, delivery timelines, and automated purchase order generation to stabilize procurement cycles.
Multi-Plant Operations Dashboard
A single, centralized view of operations across all three manufacturing plants—supporting faster, data-backed decisions at leadership and plant levels.
Technologies Applied
- ERP Platforms
- IoT Sensors
- Cloud Infrastructure
- API Integrations
- Data Analytics
The Outcome
- 72% reduction in unplanned downtime within six months
- Order fulfillment accuracy improved from 84% to 98%
- 65% reduction in supplier delivery delays
- 40% faster decision-making through consolidated operational data
- USD 1.2M+ annual savings in maintenance costs
- ERP architecture validated for future expansion to 5+ plants