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Case Study - Chemical Manufacturing

How Connected Execution Delivered $15M in Annual Maintenance Savings Enterprise-Ready Scale on AWS

Standardizing Operations, Maintenance, Warehouse, and Safety on one platform—integrated with SAP + OT systems and scaled on AWS.

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About the Customer

A leading petrochemicals and polymers manufacturer with a major North American footprint, anchored in the U.S. Gulf Coast petrochemical corridor (Texas–Louisiana) and corporate presence in the Greater Houston region. The company operates complex, asset-intensive facilities where safety, compliance, and execution consistency are non-negotiable. With thousands of frontline workers across sites, the organization relies on disciplined operational routines to protect people, maintain reliability, and keep production running without interruption.

“Adopting Innovapptive has fundamentally changed how our frontline teams operate—work is clearer, faster, and far more connected across shifts and sites. What surprised us most was how naturally the platform fit into daily routines, driving adoption and accountability without forcing change.”

Anonymous

Director of Operations, Global Chemical Manufacturer

The Problem

  • Cost takeout mandate lacked execution control: Savings targets were set, but plant leaders couldn’t consistently translate them into verified frontline actions.
  • Paper-Based Rounds and Checklists: Operator rounds and checklists lived on paper/Excel, causing missed steps and delayed visibility.
  • Audit gaps + compliance risk: Paper records and inconsistent routines led to audit findings and regulatory fines.
  • Disconnected frontline teams: Operations and maintenance worked in silos with weak handovers and no shared real-time view. Low PM:CM
  • Limited proof of work: No reliable, timestamped evidence of completion, exceptions, and corrective actions.

The Innovapptive Solution

Connected Worker Platform

  • Digital Operator Rounds (Reliability + Compliance): Standardized mobile rounds, exception capture, and audit-ready records to reduce variability and prevent incidents.
  • Mobile Work Execution (Productivity + Cost): Convert findings into work orders, accelerate closure, and capture proof-of-work to cut backlog, rework, and overtime.
  • Value Dashboards (Verified Cost Takeout): Leader-ready dashboards to track execution, savings drivers, and KPIs—turning activity into measurable outcomes.
  • Historian/SCADA Integrations (Speed to Action): Connect OT signals to frontline workflows so issues are detected early, routed fast, and closed with traceability.

The Impact

  • $15 Million Maintenance cost saved (annual)
  • 1,000+ Users Adopted within 7 months
  • 15% PM/CM Improvement Less reactive maintenance, lower disruption, better cost control.
  • Site Expansion Deployed across 18 active sites, with 2 additional sites planned for Q1 2026
  • ZERO Safety Incidents Supported by standardized, auditable execution and faster issue closure.

The Technology Stack Powering $15M in Annual Value

A comprehensive ecosystem bridging the Physical Plant (OT), the Enterprise System of Record (SAP), and the Innovapptive Execution Layer—powered by scalable AWS infrastructure.

Innovapptive Execution Layer
"Digitizing the 80% of Unstructured Field Data"

Mobile Operator Rounds

Shift Handover

Intelligent Maintenance Suite

Backoffice Control Centres

Value360 Dashboards

IoT Connectors

AI Agents

RACE (No-Code Engine)

System of Record

Work Orders, Inventory, Assets

Integration Layer

AWS AppSync & Amplify

AWS Cloud Infrastructure

Ingestion
  • AWS MQ
  • Kafka
Processing
  • AWS EKS
  • Lambda
Storage
  • S3
  • DynamoDB
Security
  • WAF
  • CloudWatch
Physical Plant & OT Layer
Equipment Assets

Pumps, Motors, Valves

IoT Sensors

Vibration, Temp, Pressure

OT Systems

PLC, SCADA, DCS

30-Second Story

How Verified Savings Happens on the Plant Floor

Innovapptive standardizes frontline execution across Operations, Maintenance, Warehouse, and Safety. Teams capture exceptions with context—photos, videos, readings, and notes—then route them to the right owners (Operations, Maintenance, or Warehouse) with clear accountability and SLAs. Collaboration happens in the workflow until the issue is closed with timestamped, auditable proof. Leaders track the value levers that matter—downtime, MTTR/MTBF, PM/CM, and maintenance spend—so hard-dollar savings are measured and verified.

What gets captured: photos • videos • readings • notes
What gets proven: closure time • compliance • cost takeout drivers
Standardize Work
Detect Exceptions
Route to Action
Close the Loop
(Proof + Collaboration)
$
Measure Value Levers → Hard-$ Impact
(Verified Savings)
Downtime • MTTR/MTBF • PM/CM • Spend
Hard-$ Savings → EBITDA Impact

One Platform. One Data Foundation. Real EBITDA Impact — Powered by AWS

Turning frontline data into verified savings.

Reliability Earlier detection → faster action
Productivity More wrench time, less rework
Safety & Compliance Audit-ready execution, fewer exceptions
Inventory Control Accurate spares, fewer expedites

Verified Hard-$ Savings → EBITDA Impact

Secure scale and governed data foundation on AWS—monitoring, compliance, and AI readiness.

Request Demo Value Creation Playbook

Quantify site-level savings potential with a joint outcomes assessment.