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