Steel Manufacturer

The Problem

Unplanned downtime consuming 30% of production → margins fell to 10%.

What Broke

Equipment failures causing 3-5 day emergency shutdowns.
Unplanned downtime eating 14% of production time.
Production parameters unchanged for 5+ years despite supplier/material changes.
Quality defects at 4.8%.

The Fix

Predictive maintenance (IoT + AI), real-time production optimization, computer vision

12 Months Later

30% productivity increase using the same equipment
90% reduction in emergency downtime
15% margin improvement
Total annual benefit: SAR 7,300,000