Manufacturing

The company transformed from a reactive, stockout-plagued operation into a demand-driven inventory organization with real-time stock visibility across its warehouse, two production staging zones, and the receiving dock. Production lines now run uninterrupted, purchasing operates on 30-, 60-, and 90-day AI-generated forecasts instead of emergency panic buys, and leadership has real-time visibility into every SKU without relying on the tribal knowledge of a single warehouse supervisor. The automated reorder engine and tiered escalation alerts eliminated the conditions that had caused recurring stockout incidents and the tens of thousands of dollars in idle labor and missed delivery windows that came with each one.

The company discovered that their perceived capacity ceiling was actually a visibility ceiling, and that the $2.1M capital investment in a fourth production line was not what their growth required. By instrumenting all three existing lines with IoT sensors and deploying real-time OEE tracking, the production analytics platform revealed a hidden bottleneck — including an intermittent sensor fault on Line 2 that had gone undetected for months — and gave operators, supervisors, and leadership the data needed to unlock significantly higher output from their existing equipment. The shift from paper-based logging and estimated downtime to 98% downtime capture and AI-powered anomaly detection fundamentally changed how the company approached production planning and capital allocation.

The company went from managing 150+ supplier relationships through spreadsheets and email to operating a centralized, audit-ready vendor management platform that gives procurement and leadership complete visibility into their supply chain. Supplier onboarding, purchase order tracking, compliance documentation, and AI-powered risk scoring now operate as a single integrated system purpose-built for the traceability demands of aerospace and defense contracting. The platform eliminated the audit exposure that had threatened the company's most valuable customer relationships and gave leadership data-driven insight into spend concentration and supplier performance for the first time.