Case Study: Optimizing a 500+ Asset Manufacturing Plant

Northern Energy Solutions

March 2025

Client Challenge: Reducing Downtime in Industrial Manufacturing

Northern Energy Solutions faced recurring downtime in their 500+ asset manufacturing facility, with unplanned maintenance costing $2M monthly. Legacy systems failed to predict equipment failures until after they occurred.

Challenges

Legacy monitoring systems • No predictive capabilities • 14% unplanned downtime

Goals

Reduce unplanned downtime by 70% • Save $1M annually • Predict equipment failures

Our Approach

Implementation Plan

Installed 300+ IoT sensors across production lines
Deployed real-time AI monitoring dashboards
Created predictive failure models using historical maintenance data

Results

13.8%

Downtime reduced

$1.2M

Annual savings

88%

Predictive accuracy

"The eam platform transformed our operations. We've reduced unplanned downtime by 13.8% and saved nearly $1.5 million in maintenance costs in the first year."
– Sarah Johnson, Operations Director