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Reducing Factory Downtime by 45% with Predictive Maintenance

Customer Overview

A manufacturing plant running heavy machinery across multiple production lines, with high operational costs associated with downtime and maintenance.

Customer Overview
Team working together

The Challenge

A manufacturing plant running heavy machinery across multiple production lines, with high operational costs associated with downtime and maintenance.The plant lacked visibility into machine health: - Unplanned breakdowns halted production - Maintenance followed a reactive schedule - No data-driven insights on machine performance - Inefficient spare parts planning

The Solution

Leapcodes implemented a smart factory toolkit: - Installed IoT sensors for vibration, temperature, and performance monitoring - Developed predictive models to forecast machine failure - Built dashboards displaying real-time operations - Automated alerts and integrated maintenance workflows into ERP

The Solution

Results Achieved

45% reduction in unplanned downtime
28% reduction in maintenance costs
ROI achieved in 7 months
30% longer equipment lifecycle
22% increase in production efficiency
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Enabling Digital Excellence

Leapcodes is a digital transformation company delivering brand marketing, custom software development, AI solutions, and cloud services across industries.

Services
Industry Solutions
Company
Contact

Kochi

Delivery Center

1st Floor, Sunpaul Blueberry, Infopark Expy, Rajagiri P.O, Kochi, Kakkanad, Kerala 682039

Bengaluru

Headquarters

1st Floor, 52, SPD Plaza 4th A Cross Road, Koramangala, Bengaluru, Karnataka - 560095

+91 88610 61626

+91 89434 15989

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