A multinational industrial manufacturer operating six large production plants faced output variability, outdated workflows, high scrap rates, and long cycle times. Despite investing in MES and ERP systems, daily operations still relied heavily on manual processes, fragmented SOPs, and paper-driven approvals. O2 Technologies partnered with the organization to modernize and re-engineer its end-to-end processes, enabling measurable improvements in efficiency, quality, and throughput.
Lack of standardization across plants resulted in inconsistent workflows, quality deviations, and unreliable reporting.
Manual data capture and paper-driven quality checks caused delays, errors, and poor visibility into real-time production status.
Scrap rates reached 18% due to late detection of defects and disconnected quality control workflows.
Maintenance operations were mostly reactive, resulting in recurring unplanned downtime across critical production lines.
O2 Technologies deployed a comprehensive multi-phase transformation program combining lean process redesign, workflow automation, digital workstations, IoT sensor integration, and AI-driven predictive analytics. The solution enabled end-to-end process visibility, faster decision-making, and a unified operating model across all plants.
Within one year, the organization achieved enterprise-wide operational transformation with measurable benefits: