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Cutting Costs and Manufacturing Defects with AI

A global plumbing fixtures company is using Pluto7's AI Platform, Planning in a Box, to lower defects and boost manufacturing performance, leading to $10 million in yearly savings.

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Industry
Manufacturing

Company size
10,001+ employees

Use Case
Preventive Maintenance

Platform Used
Planning in a Box

$10M

in annual savings

25%

decrease in production downtime

1.5M

SAP records analyzed for quality insights

THE CHALLENGES

The company struggled with 8-10% product defects per batch due to inconsistent raw materials and production variability, causing significant financial losses from waste, rework, and missed deadlines.

  • Managing an 8-10% defect rate per batch.
  • Frequent production halts for defect correction.
  • Difficulty in pinpointing root causes of defects.
  • Limited predictive maintenance capabilities.
  • High scrap rates increasing operational costs.
  • Customer complaints and returns impacting brand reputation.
  • Lack of integrated data platform for comprehensive analysis.

THE SOLUTION

Intelligent AI Platform Delivering Real-Time Quality Control Insights

The plumbing fixtures company leveraged Pluto7’s Planning in a Box to analyze and synthesize data, creating scalable AU models on Google Cloud. They established a centralized data foundation, integrating raw material checks, environmental conditions, and production metrics. This provided real-time insights for predictive maintenance and precise adjustments. As a result, defect rates were significantly reduced, ensuring consistent product quality and substantial cost savings.

Production Yield Increased by 20%

AI enhancements boosted production yield, increasing overall output and efficiency.

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Scrap Rate Decreased by 30%

AI-driven material usage optimization reduced scrap rates, enhancing overall efficiency.

Inspection Time Cut by 40%

Automated quality checks sped up the inspection process, reducing time and increasing productivity.

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  • BigQuery
  • Vertex AI

Learn More

Contact our team to see how Pluto7 can help you improve manufacturing efficiency.