Digital Transformation Consulting

The case study highlights how a manufacturing client faced niche issues related to optimizing asset performance and reducing downtime in a highly automated industrial environment. The client struggled with high repair costs, as fixing failed assets proved to be 1.8 times more expensive than addressing issues proactively before failures occurred, and lacked an integrated approach to monitor asset health in real-time. They also faced inefficiencies in utilizing data from connected devices, with only 40% of global manufacturers leveraging analytics to identify operational improvements, which hindered their ability to enhance safety, productivity, and sustainability.

To address these challenges, the tailored solution involved integrating advanced AI-powered analytics, digital twin technology, and connected asset management systems. This enabled the client to shift from reactive maintenance to predictive and proactive strategies, improving risk assessment and asset reliability. The solution also included deploying performance monitoring tools like the Asset Data Analysis Processing Tool (ADAPT) and leveraging digital twin simulations to optimize workflows, reduce unplanned downtime, and enhance asset lifecycle management. Further, the client adopted change management programs to upskill their workforce, ensuring smooth adoption of new technologies and processes, which supported increased workforce productivity and safety.

As a result of this customized approach, the client achieved specific, quantifiable improvements such as increased production throughput, reduced maintenance costs through optimized processes, and enhanced asset performance reliability. These measures contributed to decreased asset downtime and fewer unplanned repairs, ultimately strengthening operational efficiency. Additionally, integrating sustainability considerations, the client was able to identify energy use reductions and improve system safety and longevity, aligning their asset management strategy with broader environmental and safety goals. The implementation demonstrated clear performance gains in asset management, cost savings, and workforce productivity, illustrating the tangible benefits of adopting intelligent asset management tailored to the client’s industry-specific needs.