From Manual Workflows and Production Downtime to Smart Manufacturing

Client Overview

The client, a family-owned automobile aftermarket parts manufacturer, has been in business for over 40 years, growing to a workforce of more than 400 people. The company specialises in manufacturing 4WD accessories such as bull bars, rear bars, wheel carriers, tow kits, and lift kits. As demand for customisation and efficiency increased, the client sought to modernise their manufacturing processes while maintaining flexibility in their operations.

Challenge

The client faced significant challenges due to the disconnect between their IT systems—Customer Relationship Management (CRM), Product Lifecycle Management (PLM), Enterprise Resource Planning (ERP), and Manufacturing Execution Systems (MES)—and their Operational Technology (OT), which included machines and control systems on the factory floor.

Key pain points included:

• Manual and Paper-Based Workflows: Order specifications and build details were handled manually, leading to frequent errors and miscommunication.
• Defects and Rework: High defect rates due to manual processes caused costly rework and waste.
• Lack of Lead Time Forecasting: Without real-time data integration, predicting delivery times were unreliable.
• Production Downtime: Scheduled and corrective maintenance reduced production capacity, impacting output and efficiency.
• Multi-Generational Equipment: The presence of old and new machinery prevented a uniform technology stack, complicating digital transformation efforts.

The company had previously received advice from a large consulting firm recommending a multi-million-dollar factory upgrade. After attempting to implement changes independently, they recognised the need for a structured, outcome-driven approach. Having heard of our approach through a past client, they contacted Anthosa Consulting to explore incremental investments that would deliver tangible business results.

Solution

Anthosa Consulting partnered with the client to co-design a strategy for transformation while aligning investment with immediate business outcomes. The engagement was structured around key initiatives:

1. 1. Vision and Strategy Definition:
      • Collaborated with the CEO and executive leadership to define a clear innovation strategy.
      • Brought together cross-functional teams to co-design a detailed transformation strategy and expected outcomes.
   2. Deploying Edge Intelligence:
      • Implemented edge-intelligence solutions to bridge the IT-OT gap, enabling seamless data flow between legacy and modern equipment.
      • Integrated an iPad application with edge intelligence to support QR code scanning, lot tracking automation, and spec verification, reducing errors and rework.
   3. Optimising Manufacturing Processes:
      • Re-engineered manufacturing workflows to accommodate aging equipment while improving efficiency.
      • Enhanced lead time forecasting accuracy, allowing better production planning and delivery commitments.
      • Increased production capacity by minimising downtime and optimising equipment utilisation.
   4. Transitioning to Predictive Maintenance:
      • Deployed temperature sensors powered by artificial intelligence (AI) using edge inference to enable predictive maintenance, reducing unexpected equipment failures and optimising machine uptime.
   5. Gaining Visibility with an Observability Tool:
      • Introduced an Observability Tool, an open-source IT and OT monitoring solution, to provide real-time insights into factory operations.
      • Created a high-level map of product manufacturing processes to technical infrastructure (and the manufacturing equipment), aligning technology investments with business goals.
   6. Experimenting with Innovations using Edge Orchestration and AI:
      • Leveraged an Edge Orchestration Platform and AI to enable remote application updates and iterative solution testing without requiring local IT staff.
      • Allowed the client to experiment with different configurations and add new capabilities over time, ensuring future-proof scalability.

• Extended Delivery Partners for Additional Capacity

1. • Engaged Anthosa’s partner ecosystem to bring additional engineering capacity to drive the strategy forward and enable rapid prototyping for innovation.

Results and Benefits

The incremental approach to digital transformation and AI adoption for driving innovation allowed the client to achieve tangible benefits within a short period:

• Reduced Defects and Rework: The implementation of QR code scanning and automated verification reduced human errors, leading to fewer defects and higher product quality.
• Improved Lead Time Forecasting: Real-time data integration enabled more accurate production scheduling and delivery estimates.
• Optimised Equipment Utilisation: Enhanced maintenance strategies increased machine uptime, improving overall production capacity.
• Future-Proofed Technology Investments: The use of artificial intelligence and edge orchestration platforms enabled a scalable and adaptable digital transformation, reducing the risk of obsolescence.

By leveraging Anthosa Consulting’s expertise in engagement orchestration, strategy accelerators, and implementation partnerships, the client successfully modernised their manufacturing operations without the need for an overwhelming, costly overhaul. The result was a streamlined, efficient, and digitally enabled production environment that positioned the business for continued growth and innovation.

What the Customer Says About Anthosa

“Anthosa Consulting provided a structured, incremental approach to modernising our operations. Their expertise in bridging IT & OT, coupled with AI-driven predictive maintenance, helped us reduce defects, improve efficiency, and scale innovation—without the need for a costly factory overhaul.”

— Clive, Chief Operating Officer

“The previous strategy consultant suggested a multi-million-dollar factory upgrade investment to drive digital transformation, which our board didn’t approve.

So, when we began working with Anthosa Consulting, we were still apprehensive about achieving a different outcome. However, the Anthosa team invested time in our factory, asked numerous questions of our team, developed practical solutions, had the entire team’s support, and posed less risk for us to implement.

The clincher was the investment plan they created, which aligned to our desired outcomes while collaborating with a group of skilled engineering partners with the capacity to support our transformation. This time, the board had the information they needed and the confidence in our ability to succeed to give us the green light.”
– Carly, Chief Technology Officer

Talk with Us Today!

Anthosa Consulting’s Innovation Strategy Accelerator enabled the client to drive innovation at scale across their organisation, improving quality, customer satisfaction and operational efficiency. If you are looking to achieve similar outcomes, schedule an introductory consultation with our team today.