How a Global Chemical Leader Transformed Maintenance | Agentic AI on AWS

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

Cost Takeout Mandate Lacked Execution Control: Plant leaders had aggressive savings targets but lacked real-time visibility to translate goals into verified frontline actions.
Paper-Based Routines & Execution Gaps: Operator rounds and maintenance logs relied on paper and spreadsheets, creating huge data entry backlogs in SAP and slowing risk detection.
High Reactive Maintenance: Emergency breakdowns dominated site capacity, elevating repair costs and lowering overall asset availability.
Compliance & Audit Exposure: Inconsistent paper records for EHS and asset integrity created regulatory audit risks.
Disconnected Workflows: Operations, maintenance, and warehouse teams worked in silos without a shared execution view or time-stamped proof of work.

The Innovapptive Solution

Connected Worker Platform

Digital Operator Rounds (Reliability + Compliance): Standardized mobile rounds powered by the AI Detect Agent for instant (sub-10s) photo/voice issue reporting and automatic fault categorization.
Mobile Work Execution (Productivity + Cost): Streamlined floor execution integrated with SAP, using the AI Plan Agent to auto-populate complete work order packages in under 20 seconds.
Digitized Instructions & Permitting: Embedded AWS-backed digital workflows leveraging AI Digitize to convert legacy physical checklists into active digital work instructions in seconds.
Value360 & Automated RCA Engines: Executive dashboards featuring automated Digital 5-Why & Fishbone Engines to rapidly isolate root causes and eliminate repeat asset failures.
AWS Cloud Infrastructure & RapidSync™: Enterprise-grade offline execution and real-time bi-directional sync powered by AWS AppSync and EKS for reliable performance in hazardous, network-shielded plant areas.

The Impact

$15M Annual Verified Cost Savings: Achieved through AI-driven waste reduction, downtime prevention, and optimized contractor/overtime spend.
15% PM/CM Ratio Improvement: Successfully shifted operations from reactive firefighting to scheduled, proactive care.
Scaled Across 18 Sites: Rapidly deployed enterprise-wide without custom code using the RACE™ no-code engine.
Zero Safety Incidents & 100% Audit Readiness: Time-stamped digital execution logs ensured audit traceability for regulatory compliance.
Higher Frontline Wrench Time: Eliminated administrative paperwork through AI automation, allowing technicians to spend more time on high-value asset care.

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.

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)

System of Record & Integration Layer

SAP as the enterprise source of truth

SAP Work Orders · Inventory · Assets

Integration AWS AppSync & Amplify

AWS Cloud Infrastructure

Scalable, secure, and governed foundation

IngestionAWS MQ · Kafka

ProcessingAWS EKS · Lambda · Amazon Bedrock & AgentCore

StorageS3 · DynamoDB · Industrial Knowledge Graph

SecurityWAF · CloudWatch

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.

Knowledge
Repository

Plant
Data

SCADA
Historians
MES
ERP / SAP
OEM Manuals
SOPs

Knowledge
Graphs

Industrial Knowledge Graph linking Assets, RCAs, Skills, Suppliers & Work History.

Industrial
AI

Industry-Specific Intelligence

Context-Augmented Generation

Prior Interactions

↓

AWS
Amazon Bedrock · AgentCore

Agentic
Workflows

15 AI Agents
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 →