99.2% uptime.
Not a target. A result.
OPC-UA, MQTT, and IoT sensors connected to ServiceNow — predictive maintenance, real-time SPC quality, and automated EHS compliance from one platform.
Built for the plant floor. Delivered with precision.
Smart Manufacturing & Industry 4.0
OPC-UA and MQTT connectors pull real-time machine data from PLCs and SCADA into a unified production dashboard refreshed every 60 seconds.
Predictive Maintenance
IoT sensors flag failures 14-21 days ahead, auto-generating work orders with technician skill code, parts list, and safety permit attached.
Supply Chain & Inventory
Bin-level inventory sensors trigger replenishment POs when stock falls below reorder point. Supplier scorecards update weekly.
Safety & EHS Compliance
SCADA and CEM sensor data flows directly into regulatory reports. Two-step escalation fires when a parameter crosses 90% of its permit threshold.
Quality Management (SPC / CAPA)
Each defect is tagged at capture with shift, operator, machine, and lot. SPC control charts fire line-stop recommendations before the process drifts out of spec.
Digital Twin & Simulation
A ServiceNow-orchestrated digital twin maps live sensor readings and maintenance history so engineers can simulate outage impact before scheduling.
Real numbers.
Real manufacturers.
SteelTech Industries
Unplanned downtime across 12 facilities cost $89M annually. 73% of failures occurred on assets that missed scheduled PMs because manual work orders were never acknowledged before due dates.
ServiceNow Predictive Maintenance with IoT sensors on 840 critical assets, automated work-order generation 21 days ahead of PM due dates, and mobile photo confirmation before closing work orders.
87% reduction in unplanned downtime
PM completion rate from 66% to 99.2% on-time
$97M annual cost savings from avoided production halts
MTBF extended from 41 days to 9 months
GlobalTech Assembly
A 23% defect rate on PCB assemblies cost $67M/year. Inspection data lived in a separate QMS — defect clusters took 19 days to trace to root cause.
ServiceNow Quality Management integrated with MES and AOI tags each defect with shift, operator, and material lot at capture. SPC fires line-stop recommendations when defects cross 2-sigma limits.
91% reduction in field defect rate over 12 months
Root-cause investigation from 19 days to 6 hours
$74M annual cost avoidance in rework and warranty claims
Zero product recalls in 18 months
ChemPro Manufacturing
Four EPA findings and $45M in fines over 24 months: 28% of daily emissions readings were missing because data entry was manual.
ServiceNow EHS Management integrated with SCADA and CEM auto-populates regulatory reports and triggers a two-step escalation when parameters approach 90% of permit threshold.
100% of regulatory reports auto-populated from live data
Permit threshold alerts actioned within 8 minutes on average
$52M in avoided fines since go-live
Zero environmental violations in 28 months
The Manufacturing Roadmap
A proven four-phase approach delivering measurable results within 24 weeks.
Discovery
- Production line analysis
- Safety compliance audit
Design & Integrate
- ServiceNow manufacturing setup
- Quality system integration
Development
- System testing
- Process validation
Deployment
- Production deployment
- Team training
Common questions.
Everything you need to know before starting your manufacturing transformation.
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