Smart Factory Transformation for a Leading Beverage Manufacturer
A North American beverage leader leveraged AI-powered predictive maintenance to eliminate bottlenecks, optimize production, and reduce costs.
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The Challenge
Frequent Breakdowns
High Maintenance Costs
Limited Machine Visibility
the client
A Beverage Manufacturing Giant
Technology Stack
- AI & ML
- Digital Twins
- Predictive Analytics
- BI Dashboards
- Oracle
Engagement Model
- Technology & Digital Integration
the impact
98%
Uptime
84%
Downtime Reduction
25%
Productivity Boost
Substantial Savings
The shift was bold.
The impact? Unmatched.
The Need
Traditional maintenance methods led to frequent breakdowns, rising costs, and limited machine visibility. The client needed a proactive, data-driven approach to optimize production efficiency and reduce downtime. CES introduced AI-powered predictive monitoring, turning reactive maintenance into a proactive strategy.
Challenges
- Unplanned Downtime: Frequent machine failures disrupted production, causing missed targets.
- High Maintenance Costs: Reactive, manual diagnostics led to unnecessary expenses.
- Limited Machine Visibility: Lack of real-time insights resulted in delayed interventions and unexpected failures.
To eliminate operational bottlenecks, CES implemented an AI-driven machine monitoring system with real-time analytics and predictive maintenance.
- Digital Twin Technology: Created real-time machine replicas for proactive performance tracking.
- AI-Powered Predictive Maintenance: Analyzed sensor data to detect failures before they occurred.
- Interactive Dashboards: Provided engineers with real-time operational insights.
- Automated Alert System: Instant notifications for preventive action.
- Seamless System Integration: Optimized workflows with existing maintenance tools.
- 98% uptime achieved through predictive maintenance and early intervention.
- 84% downtime reduction, ensuring continuous production with minimal disruptions.
- 25% productivity surged as engineers spent less time diagnosing issues.
- Real-time monitoring cut scrap rates from 3.6% to 0.8%,improving product quality.
- Significant cost savings in operational and maintenance, bolstering long-term financial sustainability.
strategic client partner
Take the Next Step
Connect with our strategic client partner Ankur Nair at ankur.nair@cesltd.com to explore solutions tailored for you.
connect now!