Digital Transformation for Manufacturing Giant
Complete ERP integration with IoT sensor network and real-time analytics dashboard for a Fortune 500 manufacturer. Legacy silos eliminated, production data unified, and decision latency reduced from days to seconds.
Business Impact
Technologies
Timeline
9 months — Discovery to Deployment
The Challenge
The client operated 14 plants across 6 countries, each running independent legacy systems for inventory, production scheduling, quality control, and maintenance. Data lived in disconnected silos — SAP instances, custom .NET applications, spreadsheets, and paper logs. Plant managers made decisions on 3-day-old data, resulting in costly overstocking, undetected quality deviations, and reactive maintenance that caused 180+ hours of unplanned downtime per quarter.
The Solution
We deployed a unified event-driven architecture connecting every plant floor via IoT sensor gateways. Apache Kafka streams production metrics, quality readings, and equipment telemetry into a real-time analytics pipeline. A React-based command center dashboard gives operations leadership a single pane of glass across all 14 plants, with AI-powered anomaly detection flagging deviations before they become incidents.