Request Demo

Find What You Need, Instantly!

discrete industry - 20250418
Powered by
Powered By AWS | Case Study - Manufacturing

8% Higher OEE & Hard Dollar Savings: How an American Manufacturer Transformed Execution with Agentic AI

Driving production efficiency and unlocking hidden capacity through AI-augmented frontline execution—no new assets or headcount required.

Request Demo Value Creation Playbook

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 planned in SAP but executed on paper, causing diagnostic latency on complex failures.
  • 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: Autonomous maintenance and standardized mobile rounds, powered by the AI Detect Agent for instant (sub-10s) photo or voice issue reporting.
  • Mobile Maintenance Execution: Streamlined floor execution for higher wrench time, augmented by the AI Plan Agent to generate planned work orders in under 20 seconds.
  • Digital Inspections: Embedded, AWS-backed inspections leveraging AI Digital Work Instructions to automatically digitize physical checklists.
  • Scalable Frontline Adoption: Rapid, ERP-friendly rollout optimized via a Low-Code Custom AI Agent Builder.
  • Value360 Dashboards: Live KPI tracking (MTTR, MTBF, savings) featuring automated Digital 5-Why & Fishbone Engines for rapid root cause analysis.

The Impact

  • 8% OEE Improvement = $10M Savings Reduced unplanned losses through AI-powered maintenance and inspections driven by real-time continuous improvement.
  • 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.
Architecture

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.

01

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 Powered by AWS AI Agentic Workflows ↓ RACE (No-Code Engine)
02

System of Record & Integration Layer

SAP as the enterprise source of truth

SAP Work Orders · Inventory · Assets
Integration AWS AppSync & Amplify
03

AWS Cloud Infrastructure

Scalable, secure, and governed foundation

Powered by AWS
IngestionAWS MQ · Kafka
ProcessingAWS EKS · Lambda · Amazon Bedrock & AgentCore
StorageS3 · DynamoDB · Industrial Knowledge Graph
SecurityWAF · CloudWatch
04

Physical Plant & OT Layer

Where value is ultimately created

Equipment AssetsPumps · Motors · Valves
IoT SensorsVibration · Temp · Pressure
OT SystemsPLC · SCADA · DCS
AI Agentic  ·  Powered by AWS

Industrial Knowledge + Agentic AI in the Hands of the Frontline

Plant data — SCADA, Historians, MES, ERP, OEM manuals, SOPs — is unified into an Industrial Knowledge Graph and orchestrated by Amazon Bedrock & AgentCore on AWS into 15 role-specific AI Agents that execute real work on the frontline.

15 AI Agents · 5 Domains

Transforming Frontline Workflows

Operations

  • AI DigitizePaper → digital in seconds
  • AI Auto-Fill–75% form time
  • AI AuthorSOPs 5× faster
  • Work Instructions+40% task completion

Maintenance

  • AI Detect40% faster issue detection
  • Troubleshooting–35% diagnosis time
  • AI Plan90% faster planning
  • AI Assist+30% wrench time

Reliability

  • AI 5-WhyRoot cause 3× faster
  • AI Action Rec.–45% repeat failures
  • AI ReferencesKnowledge 80% faster

Safety

  • AI PPE Check–90% violations
  • AI Permits + JHA–70% approval time

Analytics

  • Automated Insights5× faster to action
  • AI Prompt InsightsInstant answers on Reports
Running on AWS

Every agent is grounded in the customer's own SAP, historian, and OT context — orchestrated by Amazon Bedrock & AgentCore across EKS, Lambda, S3, DynamoDB, and the Industrial Knowledge Graph.

See the AI Agents in action →