Case Studies

Aerospace / Defense — Defense Systems Manufacturing

Aerospace Defense Contractor Tracks Inspection Response Across 20 Production Lines

91 call buttons deployed across 20 lines. In-process inspection calls tracked from request to completion for the first time.

20 production lines with multiple inspection stages per line 7 min read

Automotive — Tier-1 Components

19-Day ROI at a 24/7 Automotive Casting Plant

Hidden idle time exposed in 48 hours. 40% faster maintenance response. Full payback in 19 days.

Multiple buildings, 75+ production lines 5 min read

Retail / Distribution — Fortune 100 Distribution Center

Multi-Department Andon Across a 2.1M Square Foot Distribution Center

200+ processing stations connected. Multi-department coordination across facilities, maintenance, and quality — with sister-plant expansion underway.

2.1 million sq ft with mezzanine 6 min read

Electronics — Connectors & Interconnects

Global Electronics Manufacturer Rolls Out Virtual Andon Across Multiple Sites

8 expansion orders in 18 months. Virtual call buttons deployed at every workstation. Multi-site rollout with enterprise-level procurement.

Multi-site manufacturing, 30+ virtual stations 7 min read

Energy — Turbine Remanufacturing

Energy Turbine Remanufacturer Tracks Response Time Across Bay-Based Layout

Plant Manager-driven deployment across all bays. Quality, maintenance, and EHS alerts unified on one system. Annual subscription renewals confirm ongoing use.

Multi-bay remanufacturing facility 8 min read

Plastics & Foam — Polyurethane Foam Manufacturing

Foam Manufacturer Turns Invisible Downtime Into Actionable Data

Equipment downtime tracked for the first time. System validated in 30 days, purchased, and scaled across fabrication areas.

Multiple production lines across fabrication areas 6 min read

Food Manufacturing — Specialty Food Production

8-Line Food Plant Closes the Quality Response Gap

Quality response time tracked for the first time. Full visibility across production, packaging, fulfillment, and warehouse.

8 production lines across multiple departments 5 min read

Medical Devices — FDA-Regulated Manufacturing

Medical Device Manufacturer Deploys Andon Across FDA-Regulated Clean Rooms

Response time tracked for the first time across clean rooms. Multi-phase deployment from proof of concept to full production coverage.

Multiple production areas including clean rooms 6 min read

Plastics / Injection Molding — Injection Molding

Plastics Injection Molder Closes the Gap Between Downtime and Response Time

Response time tracked for the first time — separate from machine downtime. System scaled to 64 watch pagers across all shifts and support teams.

Multi-line injection molding facility, 3-shift operation 7 min read

Automotive — Truck & Trailer Components

From Trial to Two-Plant Rollout at a Truck Components Manufacturer

Pilot expanded to 49 virtual Andon stations across two plants. Full switch from physical buttons to virtual buttons driven by operator adoption.

Two manufacturing plants, 50+ workstations 6 min read