High maintenance costs, unexpected downtimes, and inefficient processes continue to challenge manufacturers. To stay competitive, companies are leveraging manufacturing analytics to optimize operations and enhance asset performance.
Explore the top 20 real-world case studies where manufacturers used analytics insights to cut costs, reduce unplanned downtime, and boost productivity.
Top 20 manufacturing analytics case studies
Updated at 06-24-2025
| Vendor | Customer | Country | Industry | Use Case | Results |
|---|---|---|---|---|---|
| Augury | Lindt | Global | Food & Beverage | Order management and risk management | Reduced maintenance costs, optimized production lines, improved output with data-driven decision-making. |
| Augury | Roseburg | USA | Forest products | Asset management | Achieved 7x ROI in under one year, improved reliability, reduced downtime across 15 facilities. |
| Augury | N/A | USA | Infant formula manufacturing | Preventive maintenance, inventory management and automation | Prevented $350,000 in system errors, enabled earlier part orders, and reduced expedited shipping costs. |
| Busroot | A1 Bacon | United Kingdom | Food & Beverage | Inventory management | Increased product output by 14 percent, reduced packaging waste and machine idle time costs. |
| FogHorn | N/A | China | EV charger manufacturing | Predictive maintenance and asset management | Reduced false positive alerts and improved anticipation of maintenance needs. |
| Konux | Deutsche Bahn | Germany | Railway infrastructure | Predictive maintenance and asset management | Reduced maintenance costs by 25 percent and minimized delay-causing failures. |
| Mu Sigma | N/A | USA | Food & Beverage | Price optimization | Identified pricing opportunities leading to a 2 to 3 percent revenue increase. |
| Mu Sigma | N/A | USA | Energy | Inventory management | Optimized excess inventory with projected annual savings of $15 million to $20 million. |
| PTC | Colfax | USA | Mechanical and industrial engineering | Predictive maintenance and asset management | Reduced service costs through remote monitoring, improved asset utilization by detecting anomalies. |
| PTC | SIG | Switzerland | Packaging and containers | Asset management and optimization | Identified micro-outages, reduced energy overconsumption, and increased production line speed. |
| Rockwell Automation | Harvest Food Group | USA | Food & Beverage | Asset management | Improved cycle count accuracy from 6 percent to 98 percent, reduced accounts receivable aging from 5 percent to 1.6 percent. |
| Rockwell Automation | The Maschhoffs | USA | Food & Beverage | Predictive analytics and automation | Enhanced space utilization and extended forecasting horizon from one year to five years. |
| Rockwell Automation | National Engineering Industries (NEI) | India | Brownfield Factory | Predictive maintenance and risk management | Enabled proactive actions, prevented unplanned breakdowns, and improved performance visibility across operations. |
| Rockwell Automation | Nói Síríus | Iceland | Food & Beverage | Predictive maintenance, asset management and optimization | Prioritized job queues, reduced unplanned callouts, and improved performance management. |
| Rockwell Automation | N/A | USA | Polymer and coating materials | Asset management and product development | Achieved 12 percent increase in production, 6 percent reduction in natural gas per ton, and 50 percent decrease in process variability. |
| SAS | Kia Motors | USA | Automotives | Asset management, product development, predictive maintenance and end user experience | Reduced production time, forecasted maintenance costs, and enabled faster dealer response through failure prediction. |
| SAS | Siemens Healthineers | Germany | Medical technology | Predictive maintenance | Reduced system downtime by 36 percent and optimized technician scheduling with parts forecasting. |
| Sight Machine | N/A | USA | Paper manufacturing | Predictive maintenance and asset management | Identified relationships between production parameters and quality, developed a digital twin of the production process. |
| Sight Machine | N/A | USA | Automotives | Asset management and risk management | Performed root cause analysis and uncovered quality issues using data modeling. |
| Sight Machine | N/A | USA | Industrial manufacturing | Asset management | Found $500,000 in potential savings within three weeks and reduced scrap costs by 30 percent. |
To explore the manufacturing analytics vendor landscape, check out manufacturing analytics software and vendors.
What are the top use cases of manufacturing analytics?
Manufacturing data, including machine and operator information, can be processed and analyzed for:
Supply chain
- Demand forecasting: Predicts future product demand using data to optimize production and inventory.
- Inventory/asset management: Tracks and optimizes the use of assets and inventory to reduce costs and prevent overstocking or stock outs.
- Order management: Manages customer orders to ensure accuracy and timeliness.
- Maintenance optimization: Uses predictive analytics to schedule equipment maintenance and minimize downtime.
- Risk management: Identifies and mitigates potential disruptions in the supply chain.
Logistics
- Automation and robotics: Improves efficiency and accuracy in manufacturing and warehouse operations through robotics and automated processes.
- Transportation allocation: Optimizes the assignment of transport resources to reduce costs and improve delivery times.
Product development
- Product progress measurement: Tracks the development stages of a product to ensure timelines and quality standards are met.
- End-user experience estimation: Evaluates how a product will meet customer needs and expectations based on data.
Sales
- Price optimization: Uses analytics to determine the best pricing strategies to maximize revenue and market competitiveness.
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