Visibility That Paid for Itself

By streamlining programming and strengthening shifts, our customer turned insight into growth and ROI.

Overview

Since October 2023, our customer in Germany has experienced a compound monthly growth rate of 3.5% in machine running time. Through targeted analysis and process visibility, this facility has successfully streamlined programming time, enabling the team to recover significant lost hours. These gains alone were sufficient to justify the deployment costs of the improvement program within the first year.

The Challenge

They faced several operational barriers, including:

- Inefficient programming processes causing delays and lost capacity

- Underutilized shift coverage, limiting production throughput

- Complications in transitioning to a new ERP system, creating workflow friction

The Solution

The Auredia deployment helped our customer:

- Quantify and reduce programming-related downtime

- Demonstrate the need for—and secure—second and third shift staffing

- Identify and address transition bottlenecks during their ERP migration. These data-backed insights enabled leadership to act decisively in strengthening operations across all shifts.

Results

- 3.5% compound monthly growth in machine running time since October 2023

- Programming time reduction paid for the system within the first year

- Operational justification for adding 2nd and 3rd shift coverage

- Increased visibility into ERP transition challenges and response planning