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Predictive Analytics Prevents 90% of Machine Failures in Manufacturing

How Dovient transformed maintenance operations for a multi-billion dollar industrial conglomerate across cement, mining, energy, and sugar manufacturing sectors

Client Overview

Industries

Cement, Mining, Energy, Sugar

Company Size

15,000+ Employees

Manufacturing Facilities

25+ Global Units

Critical Assets

5,000+ Equipment

Operations

24/7 Continuous Production

Geographic Presence

4 Continents

A diversified industrial conglomerate with operations spanning multiple heavy industries including cement manufacturing, mining operations, thermal power generation, and sugar processing. The company operates across multiple continents with a focus on sustainable industrial practices and operational excellence.

The Challenge

Managing massive scale operations with complex equipment interdependencies across diverse industrial sectors

Scale Complexity

Massive operations across 25+ facilities with complex equipment interdependencies and varying maintenance requirements

Unplanned Downtime

Critical equipment failures costing millions per hour in lost production and emergency repairs

Fragmented Systems

Different maintenance systems across plants leading to inconsistent processes and data silos

Limited Visibility

Lack of real-time visibility into equipment health across diverse industrial operations

Our Solution

Unified maintenance platform with industry-specific modules for diverse operations

1

Unified CMMS Platform

Implemented single, scalable maintenance management system across all 25+ facilities and business units with industry-specific configurations for cement, mining, energy, and sugar operations.

2

IoT-Enabled Predictive Maintenance

Deployed advanced IoT sensors and machine learning algorithms to predict equipment failures before they occur, reducing unplanned downtime by 35%.

3

Centralized Spare Parts Management

Optimized inventory management with automated procurement, cross-facility sharing, and demand forecasting, reducing inventory costs by 50%.

4

Real-Time Dashboards & Mobile Workforce

Executive dashboards with real-time KPIs and mobile applications for field technicians, enabling data-driven decisions and efficient workforce management.

35%
Downtime Reduction
Unplanned Equipment Failures
45%
Faster Response
Maintenance Requests
50%
Inventory Optimization
Spare Parts Management
28%
Productivity Increase
Overall Operations

Implementation Timeline

Phased rollout across multiple industries and facilities

1

Week 1-2

System architecture design and pilot facility selection

2

Week 2-4

Pilot implementation and industry-specific customization

3

Week 5-8

Phased rollout across all facilities by industry

4

Week 9-12

Full deployment and advanced analytics integration

"The scale of transformation Dovient delivered across our diverse industrial portfolio is remarkable. We've achieved unprecedented operational efficiency while significantly reducing our maintenance spend. The unified platform has given us visibility and control we never had before across cement, mining, energy, and sugar operations."
Rajesh Kumar
Chief Operations Officer

Ready to Transform Your Multi-Facility Operations?

Join industrial leaders who have revolutionized their maintenance operations across diverse sectors with Dovient's unified platform.