Actionable Data: Reducing Unplanned Downtime with Real-Time BI
| Consolidating disparate data sources into a single BI dashboard, enabling real-time decision-making and improving asset utilization across plant operations. Our BI strategy provided plant and executive leadership with immediate, visualized intelligence on production health, dramatically reducing unplanned downtime and material waste. |
Our Challenge
The client collected vast amounts of production data, but it was scattered across disparate legacy systems, making real-time decision-making impossible. Plant managers lacked the consolidated, visualized view necessary to spot production inefficiencies, predict maintenance needs, or monitor energy usage.
Our Solution (The Approach): We implemented a Business Intelligence (BI) strategy starting with data consolidation and governance. We designed and deployed a central Operational Intelligence Dashboard, utilizing modern data visualization tools to present complex data—such as equipment uptime, defect rates, and supply chain KPIs—in clear, actionable formats tailored to executive and plant floor audiences.
The Result Of Project
Tangible Impact: The project democratized access to operational data, empowering managers to identify and correct costly production issues instantly rather than waiting for weekly reports.
Results & Long-Term Value:
- Identified and mitigated sources of waste, leading to a 12% reduction in material costs.
- Improved predictive maintenance accuracy, reducing unplanned equipment downtime by 18%.
- The BI platform now serves as the single source of truth for all operational performance metrics.
- Provided training for over 50 staff members on data literacy and dashboard utilization.
