The Challenge: Legacy Scaling in a 24/7 Environment
Aggressive expansion led to paper-based workflows and fragmented IT support that created bottlenecks across mission-critical production and logistics sites.
- Manual Inefficiencies: Paper-based inventory tracking led to fulfillment delays and data inaccuracies.
- Scaling Constraints: Needed to scale IT support from 4 to 22 sites without compromising operational reliability.
- Production Risk: Downtime in automated material handling directly impacted plant throughput.
The Strategy: Industrial IT Modernization
The transformation integrated IT directly into the plant floor, aligning technology delivery with manufacturing and safety objectives to drive shift productivity.
1. Mobile Computing & Warehouse Automation
Designed and led the rollout of forklift-mounted mobile computing systems, eliminating manual data entry and driving a 62% increase in first-shift productivity.
2. Standardizing the Operational Playbook
Developed comprehensive SOPs and "train-the-trainer" programs to ensure technical readiness and enable rapid onboarding of new facilities.
3. OT/IT Alignment & Continuous Improvement
Served as the primary IT advisory lead for 5S and continuous improvement, aligning support with automated material handling systems.
4. Scalable Logistics & Provisioning
Centralized warehouse-based imaging and shipping operations, increasing provisioning throughput by over 60%.
The Results: Measurable Operational Throughput
The transition to automated, standardized operations provided the foundation for sustained growth and superior manufacturing efficiency.
- Revenue Impact: Increased shift productivity by over 60% through the elimination of paper-based logistics.
- Rapid Site Scaling: Successfully expanded IT operations from 4 to 22 sites while maintaining high resolution rates for production incidents.
- Mission-Critical Resilience: Ensured 24/7 service availability for networks and control systems across North American facilities.