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Powered By AWS | Case Study - Manufacturing

9,000 Hours Recovered: How Sabert Reclaimed Production Capacity with Agentic AI Workflows on AWS

Leveraging Frontline AI to standardize maintenance execution, unlocking the equivalent of two production lines and deferring $16M in CapEx.

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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

  • Invisible Cost Leaks: Work wasn’t captured at source—driving rework, delays, and unplanned spend.
  • Rising Unplanned Downtime: Unplanned downtime grew year-over-year—27,000 hours across sites driving lost capacity and cost pressure.
  • Invisible Work in SAP: Field execution often didn’t reach SAP in a usable form—limiting visibility, governance, and reporting.
  • Reactive Maintenance Cycles: Poor data quality prevented effective preventive maintenance planning.
  • Lost Production Capacity: Thousands of downtime hours pushed the business toward new asset investment.

The Innovapptive Solution

Connected Worker Platform

  • Digitized Mobile Maintenance Execution: Deployed a mobile execution layer natively integrated with SAP, empowering technicians with the AI Plan Agent to auto-generate work orders and the AI Assist Agent to instantly retrieve troubleshooting guides.
  • Automated Structured Digital Inspections: Embedded AWS-backed digital inspections, leveraging the AI Digitize Agent to instantly convert legacy paper checklists into active digital forms—slashing manual form creation time by 75%.
  • Implemented a Maintenance Control Center: Rolled out modern, AWS-hosted executive Kanban dashboards featuring AI 5-Why Engines to rapidly analyze backlogs, aging work, and isolate root causes.
  • Centralized Spare Parts Control: AWS-based inventory dashboards and kanban controls to reduce stockouts, expedite spend, and maintenance delays.

The Impact

  • $10–$16M Capex Deferred: New production lines deferred by reclaiming existing asset capacity.
  • 9000 Hours Recovered: Annual unplanned downtime eliminated through disciplined maintenance execution.
  • 2 Lines of Capacity Unlocked: Equivalent production capacity recovered without new asset investment.
  • 23% Higher Technician Productivity: More wrench time and faster closures—less time lost to manual documentation.
Watch the Story

Building Execution Discipline at the Frontline

Hear from Sabert’s operations leaders on how Innovapptive captured execution at the source to standardize workflows, improve cross-shift visibility, and enable a predictable operating model that scales across sites.

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 →