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Manufacturing Asset Management Case Study — DigitoWork
Case Study  ·  Manufacturing Operations

Cutting Unplanned Downtime by 71% Across a Multi-Plant Manufacturing Network

How a large-scale manufacturing enterprise eliminated asset blind spots across five production plants — automating maintenance cycles, reducing breakdowns, and achieving full regulatory traceability from shop floor to boardroom.

Client
Confidential
Sector
Heavy Manufacturing
Scale
5 Plants · 6,200+ Assets
Duration
16 Months
71%
Reduction in unplanned downtime
₹3.4Cr
Annual cost savings achieved
48%
Faster maintenance turnaround
100%
Asset traceability across all plants
Client identity withheld under NDA. All metrics and insights shared with explicit client approval.

Five plants. Zero unified asset visibility.

✗
Unplanned breakdowns halting production
Critical machinery failed without warning across plants, causing production stoppages averaging 14 hours per incident — at a cost of ₹8–12 lakhs per event.
✗
No cross-plant asset visibility
Each plant maintained its own disconnected register. Spare parts and tools were duplicated across facilities while shortages occurred in others.
!
Manual, paper-based maintenance logs
Technicians logged maintenance in paper registers. Critical service history was lost when staff changed, leading to repeated failures on the same machines.
!
Regulatory traceability gaps
ISO and factory compliance audits repeatedly flagged missing calibration records, incomplete maintenance histories, and unverifiable asset lifecycles.

A structured, plant-by-plant digital transformation

Phase 1 · Months 1–3  ·  Asset Census

Full inventory audit across all five plants

A ground-up physical audit of 6,200+ assets — machinery, tools, vehicles, electrical equipment, and safety assets — across all five manufacturing facilities. Each asset photographed, condition-rated, and entered into a unified digital register with full procurement and service history captured where available.

Phase 2 · Months 4–7  ·  Digital Infrastructure

IoT sensors, QR tagging & centralised platform

Every asset tagged with industrial-grade QR + RFID labels designed for shop floor environments (oil, heat, vibration resistant). IoT vibration and temperature sensors installed on 340 critical machines for real-time health monitoring. All data fed into a single cloud-based asset management platform with role-based access for plant managers, technicians, and corporate teams.

Predictive maintenance architecture, full ROI model, plant manager testimonials and implementation blueprint
are all in the complete case study PDF — free to download.

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