Confidential

Manufacturing

AI-Driven Automation and Cloud Scalability for a Modern Manufacturer

A large industrial manufacturing firm with global supply chains needed to improve production monitoring, automate reporting, and ensure system scalability. Their legacy ERP system was rigid and difficult to scale, integration between factory sensors and digital platforms was broken, and deploying updates across global plants took too long. They also lacked a unified data layer for analytics.

7 months
Duration
4
Team Size
Large
Company Size
completed
Status
AI-Driven Automation and Cloud Scalability for a Modern Manufacturer

Technologies Used

AWS (EC2, EKS, CloudWatch, S3)
Kubernetes, Docker
Python, FastAPI, Kafka
PostgreSQL, InfluxDB
PLC integrations, MQTT

Services Provided

AI Workflow Automation
DevOps as a Service
Cloud Infrastructure & Migration

Our Solution

Zabrizon deployed a full-stack modernization strategy tailored for industrial use. The first step involved lifting the ERP backend and production data lakes to AWS, establishing multi-region failover capabilities and isolating OT networks for improved security and resilience. We then introduced AI agents that analyzed IoT sensor data in real-time, enabling predictive maintenance and significantly reducing unexpected downtime. To facilitate seamless integration across factory systems, we developed a robust API layer that connected PLCs, inventory management tools, and predictive analytics platforms. Alongside this, we implemented a containerized microservices architecture with CI/CD pipelines spanning three continents, ensuring consistent, rapid deployments across global plants. Finally, we launched a lightweight SaaS application designed specifically for factory managers, offering real-time dashboards to monitor equipment health, production KPIs, and historical incident data.

Key Features Delivered

Predictive Maintenance AI

Real-time monitoring and failure prediction from sensor data

Real-time monitoring and failure prediction from sensor data Connected Factory APIs

Seamless data exchange between ERP, PLCs, and apps

Global DevOps Framework

Unified CI/CD strategy for plants across three continents

Measurable Results

48%
Reduction in Downtime
AI-driven anomaly detection flagged issues before failures
3x
Faster Global Software Rollouts
Containerized delivery and DevOps pipelines sped up deployments
60%
Improved Data Visibility
Unified dashboard helped management take faster decisions

Project Timeline

1

Infra Audit & Risk Analysis

3 weeks

Deliverables:

  • (3 weeks) OT/IT network segregation planning
  • Factory asset mapping
2

Cloud Migration & Edge Connectivity

6 weeks

Deliverables:

  • ERP backend move to AWS
  • MQTT & PLC integration setup
3

DevOps + API Layer

10 weeks

Deliverables:

  • CI/CD setup for multi-region
  • Unified API layer across tools
4

AI & SaaS Rollout

9 weeks

Deliverables:

  • Train and deploy predictive models
  • Launch factory dashboard SaaS

Ready to Transform Your Business?

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