---
title: IDSTS - Uncovering the true baseline of efficiency
description: Contact IDSTS
image: https://idsts.com/hubfs/IDSTS%20Logo.png
---

###### Case study

#### Manufacturing case study

---

## **Paving the way to $400M+ value with real-time production visibility and automated OEE tracking for a leading aircraft manufacturer**

IDSTS helps a leading global aircraft manufacturer automate OEE tracking, providing real-time production visibility and modeling $400M+ in potential throughput and cost improvements.

## At a glance

 

##### Industry

Aerospace & Defense/Manufacturing

 

##### Location

Global

 

##### Challenge

Manual OEE tracking led to inaccurate efficiency reporting across ~250 machines

##### Challenge

 

- Over $400M projected in modeled financial impact
- Over 10% hidden efficiency gap identified

## The challenge

![the_challenge-4](https://idsts.com/hubfs/the_challenge-4.webp "the_challenge-4")

****Manual tracking masked true performance****

 

A global aerospace manufacturer operated a complex production landscape of ~250 machines across its aircraft and aviation systems facilities. Overall equipment effectiveness (OEE) was manually calculated using operator-entered data, which introduced discrepancies and led to inaccurate performance metrics.

 

****Inaccurate data hindered decision-making****

 

These inaccuracies not only masked inefficiencies but also hindered the client’s ability to accurately measure and improve plant throughput. The organization needed a data-driven, scalable solution to uncover the true baseline of OEE and support strategic decisions around investments, performance improvements and future scalability

## Our approach

IDSTS conducted a comprehensive multilayered assessment and developed a solution tailored to the client’s production environment:

- Site and technical assessments: We evaluated key production sites, machinery, architecture and data systems to understand the existing OEE calculation mechanisms
- Data discrepancy analysis: Our team analyzed the OEE input methods and formulas to identify overreporting issues and root causes
- Tailored OEE model design: We developed a custom-fit OEE model aligned to the client’s operational parameters
- To-be architecture and rollout planning: Future-state architecture was designed to support full-scale deployment across plants, along with a phased implementation roadmap
- Business case development: We quantified the ROI potential by modeling the impact of correcting OEE underreporting, establishing a clear link between data integrity and throughput gains

![our_approach-5](https://idsts.com/hubfs/our_approach-5.webp "our_approach-5")

## **Business outcomes**

![business_outcomes-7](https://idsts.com/hubfs/business_outcomes-7.webp "business_outcomes-7")

#### Uncovering the true baseline of efficiency

 

Automating OEE tracking highlighted discrepancies that, if addressed, could lead to over 10% improvement in operational efficiency. The modeled benefits included higher throughput, deferred capital investments and reduced unit costs, representing over $400M in potential value.

IDSTS OEE automation approach provided the client with accurate performance baselines and insights into hidden inefficiencies. Based on these findings, the projected benefits include: 

- #####  ****$16M**** 

projected in CapEx avoidance over three years

- ##### ****10%+****

hidden efficiency gap identified

 

These results are modeled projections based on identified OEE gaps and expected operational improvements. Future phases will focus on scaling the solution across all production lines.