Turn Data into ROI in 3 Months — 95% Time Saved & 20% Fewer Stops

Client Overview

A multi-plant manufacturer operating across North America needed faster, trustworthy visibility into equipment downtime and incidents. Reliability data lived in separate systems and spreadsheets, making comparisons slow and decisions reactive.

Project Summary

Ray Business Technologies unified incident and downtime data in Microsoft Fabric (OneLake) and delivered governed semantic models, role-based Power BI dashboards, and a conversational Copilot layer. Leaders can now ask questions in plain language and get instant, decision-ready answers.

Challenges

• Fragmented logs across CMMS/EAM, MES, and spreadsheets with inconsistent definitions
• Slow reporting cycles and manual reconciliations that delayed action
• Limited self-service, heavy reliance on IT report queues
• Low confidence in KPIs like downtime, availability, MTBF, and incident rate

Solutions Implemented by Ray Business Technologies

 

• Unified data foundation: Ingested incident and downtime tables into OneLake via Data Gateway and Azure Data Factory with scheduled, automated loads
• Business-ready semantics: Standardized metric definitions, hierarchies, and relationships for plant → line → machine analysis
• Analytics & dashboards: Curated Power BI models with drilldowns, trend views, and variance analysis by shift, product, and cause code
• Conversational insights: Enabled Power BI Copilot with synonyms and examples so users can ask natural questions and get instant visuals
• Governance & enablement: Role-based security, lineage, refresh policies, plus training, playbooks, and adoption KPIs

Business Benefits

 

•  Speed to insight: Report prep drops from 4–6 hrs to <1 min (≈95% faster), enabling same-shift action.
• Downtime reduction: Target 10–20% fewer unplanned stops in 90–120 days; MTTR −15–25%, MTBF +10–15%.
• Throughput & service: OTIF +3–6 pts, line cycle time −5–10%, fewer expedites (−20–30% freight spend).
• Cost control: Overtime −10–15%, scrap tied to repeat incidents −8–12%; inventory accuracy +2–4 pts.
• Single source of truth: 100% metric alignment across plants; reconciliation errors −90%.
• Lean IT load: Ad-hoc BI ticket volume −60–80% via self-service models and Copilot Q&A.
• Payback window: Typical pilot-to-scale ROI in 3–6 months, depending on baseline downtime and mix.

Achieving Operational Excellence

With a clean semantic layer and conversational analytics, the manufacturer now runs a continuous improvement loop: weekly KPI reviews, targeted actions against the top downtime causes, and monthly value checkpoints. Next steps include incremental refresh for near real-time views, predictive maintenance models, and expanding the blueprint to quality, energy, and procurement—turning insights into sustained operational gains.

About Ray Business Technologies

Ray Business Technologies is a Global Information Technology (IT) Services and Solutions company. We are a CMMI Level 3 company, providing cutting-edge IT Solutions to Enterprises worldwide, enabling them to utilize available resources effectively and manage the operations. Our excellent team of Technology Professionals work with enterprise clients in North America, Latin America, Australia, Europe, Middle East and Asia.
www.raybiztech.com