Digital transformation boosts production capacity growth by 37%

The manufacturer needed a strategic partner that could simultaneously solve immediate capacity constraints and develop a foundation for digital operations. Our previous work on their distribution analysis demonstrated our unique combination of manufacturing expertise and technology capabilities. We quickly identified two parallel opportunity paths: implementing integrated operations management to optimize current processes while deploying industrial IoT technology to create the data backbone for future digital growth. By integrating these systems, we boosted weekly production by 37% and built the digital factory capabilities needed to support long-term innovation and scalability.

Over a six-month engagement, we partnered closely with the client to roll out improvements across four departments and 31 machines. We worked side-by-side with the client team, orchestrating change across multiple fronts. By collecting and analyzing operational data, we introduced new metrics, scorecards, and communication practices that created clarity and alignment. We also implemented the SORBA platform, connecting machines to create a centralized data source. With daily coaching across all shifts, we equipped everyone—from leadership to line operators—to adopt the tools and sustain meaningful performance gains.

The manufacturer now has real-time insight into equipment effectiveness, production rates, and downtime—data that once took hours to compile. With instant visibility, employees communicate more effectively between shifts and respond faster to issues, reducing lost production time. These changes translated into a 37% boost in production capacity and $13.1 million in additional annual revenue, delivering full ROI in just 16 weeks. Just as important, we sparked a cultural shift: Operators actively engage with performance metrics, comparing shift results and driving continuous improvement. The data foundation we built powers both immediate gains and long-term transformation.