Multi-Plant Predictive Operations & Supply Chain

Unified real-time visibility, predictive maintenance, and constraint-aware scheduling across a four-plant manufacturing network -- cutting unplanned downtime by 60%.

45%

Planning time eliminated

95%

Demand forecast accuracy

+18%

OEE improvement

60%

Unplanned downtime cut

The Challenge

Siloed data and reactive firefighting across every plant.

Inventory blind spots caused line-down events multiple times per quarter, triggering expensive air-freight expedites

Supply disruptions were caught reactively -- by the time procurement knew, the damage was done

Demand forecasts went stale within days due to frequent engineering change orders and seasonal swings

ERP, MES, WMS, and machine telemetry lived in separate silos with no unified operational view

Unplanned downtime suppressed OEE across four plants, costing millions in lost throughput annually

The Solution

Unified intelligence that predicts, schedules, and executes.

Unified streaming ingestion pulls real-time signals from PLCs, IoT sensors, ERP, MES, and WMS into one platform

Predictive models flag equipment anomalies and quality drifts 48-72 hours before they become failures

Probabilistic demand engine recalibrates forecasts daily, auto-adjusting safety stock and reorder points

Constraint-aware scheduler sequences work orders across four plants, balancing load, tooling, and labor

Every recommendation pushes back into existing systems for one-click approval -- no copy-pasting between tools

Process

End-to-end closed-loop orchestration.

Step 01

Data Unification

Real-time ingestion from PLCs, IoT sensors, ERP, MES, and WMS. Every data point lands in a single operational lake within seconds.

Step 02

Predictive Intelligence

ML models trained on your historical data predict equipment failures, quality drifts, and demand shifts with 95% accuracy -- 48 to 72 hours ahead.

Step 03

Adaptive Scheduling

Constraint-aware optimizer auto-sequences work orders across plants. Balances tooling, labor, maintenance windows, and due dates in real time.

Step 04

Closed-Loop Execution

Recommendations push directly into ERP and MES for one-click approval. Feedback loops retrain models continuously so accuracy improves over time.

Technology

Industrial-grade stack.

ERP / MES / WMS

PLC & IoT Sensors

ML Prediction Engine

Optimization Solver

Real-time Analytics

Workflow Automation

Ready to optimize your operations?

See how predictive analytics and intelligent scheduling can transform your manufacturing network.

Book a demo More case studies