The Challenge
GlobalMakers Inc. operated 30 plants across four continents with no consistent way to monitor equipment health. Unplanned downtime cost the company an estimated $42M annually, and production planners worked from week-old data.
Our Approach
We deployed an IoT and analytics platform connecting 12,000 sensors to a unified data lake, with edge processing at each plant and predictive maintenance models running in the cloud.
Capabilities Delivered
- Real-time OEE dashboards refreshed every 5 seconds.
- Predictive maintenance models flagging anomalies 7-14 days in advance.
- Digital twin of each production line for what-if scheduling.
- Secure remote-support tooling for plant engineers.
Results
Unplanned downtime dropped 55%, plant-level throughput rose 38%, and the centralised platform now ingests data from 12,000+ connected sensors across the network.