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
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Over $400M projected in modeled financial impact
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Over 10% hidden efficiency gap identified
The challenge
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:
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Site and technical assessments: We evaluated key production sites, machinery, architecture and data systems to understand the existing OEE calculation mechanisms
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Data discrepancy analysis: Our team analyzed the OEE input methods and formulas to identify overreporting issues and root causes
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Tailored OEE model design: We developed a custom-fit OEE model aligned to the client’s operational parameters
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To-be architecture and rollout planning: Future-state architecture was designed to support full-scale deployment across plants, along with a phased implementation roadmap
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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
Business outcomes
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:
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$16M
projected in CapEx avoidance over three years
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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.