How an American Manufacturer Drove a 8% OEE Improvement Unlocking Hard-$ Cost Savings
Increasing Production Efficiency Without Adding Assets or Headcount
About the Customer
The customer is a major American multinational that manufactures essential personal care and paper-based consumer products used by millions every day. With a broad network of asset-intensive manufacturing facilities, the organization operates in highly regulated environments where safety, reliability, and execution discipline are non-negotiable. Its operations depend on seamless coordination between maintenance teams, inventory and storeroom managers, inspectors, and frontline operators—working across shifts, sites, and enterprise systems to keep production running smoothly and compliantly.
“Innovapptive helped us bring structure and accountability to frontline execution in a way we simply didn’t have before. By connecting maintenance, inventory, and inspections into one execution layer, we’ve been able to drive measurable improvements in reliability and production efficiency.”
Director of Manufacturing Excellence
Global Chemical Manufacturer
The Problem
- Disconnected Maintenance Execution: Work was planned in SAP but executed on paper, creating gaps between plan and reality.
- Inventory Delays at the Frontline: Limited visibility into spare parts caused maintenance delays and inefficiencies.
- Manual, Inconsistent Inspections: Paper-based inspections slowed issue detection and increased compliance risk.
- Lack of Real-Time Visibility: Supervisors had little insight into work status, material usage, or inspection outcomes.
- Siloed Frontline Processes: Maintenance, inventory, and inspections operated independently, limiting execution discipline.
The Innovapptive Solution
Connected Worker Platform
- Digital Operator Rounds: Standardized mobile rounds, exception capture, and audit-ready records to reduce variability and prevent incidents.
- Mobile Maintenance Execution: Standardized work execution on the floor—clean work history, higher wrench time, and fewer execution-driven delays.
- Digital Inspections: Inspections built on AWS and embedded into work execution—capturing photos, evidence, and reliability data beyond standard work orders.
- Scalable Frontline Adoption: Designed for rapid rollout across roles without disrupting core ERP processes.
- Value360 Dashboards: Live capture of value KPIs—MTTR, MTBF, unplanned downtime, contractor spend, and total cost savings—with AWS-grade governance.
The Impact
-
8% OEE Improvement = $10M Savings Reduced unplanned losses through disciplined maintenance and inspections.
-
12% Increase in Production Efficiency Higher sustained run rates with fewer execution-related stoppages.
-
20% Reduction in Maintenance-Related Downtime Issues resolved earlier through accurate, real-time execution data.
-
20% Faster Work Order Completion Less waiting, less paperwork, and fewer rework cycles.
-
Higher Output Without Additional Capital Spend Recovered capacity met demand using existing assets.
The Technology Stack Powering 8% OEE Improvement
A comprehensive ecosystem bridging the Physical Plant (OT), the Enterprise System of Record (SAP), and the Innovapptive Execution Layer—powered by scalable AWS infrastructure.
Mobile Operator Rounds
Shift Handover
Intelligent Maintenance Suite
Backoffice Control Centres
Value360 Dashboards
IoT Connectors
AI Agents
RACE (No-Code Engine)
System of Record
Work Orders, Inventory, Assets
Integration Layer
AWS AppSync & Amplify
AWS Cloud Infrastructure
- AWS MQ
- Kafka
- AWS EKS
- Lambda
- S3
- DynamoDB
- WAF
- CloudWatch
Pumps, Motors, Valves
Vibration, Temp, Pressure
PLC, SCADA, DCS
One Platform. One Data Foundation. Real EBITDA Impact — Powered by AWS
Turning frontline data into verified savings.
Verified Hard-$ Savings → EBITDA Impact
Secure scale and governed data foundation on AWS—monitoring, compliance, and AI readiness.
Quantify site-level savings potential with a joint outcomes assessment.