We helped a global manufacturer boost equipment effectiveness, reduce downtime, and drive efficiency across its production network.
Client
Ironclad Manufacturing Co.
Industry
Manufacturing
Services
Operational Excellence
Company Size
12,000+ Employees
Location
Detroit, USA
Timeline
Jan 2026 – Oct 2026
Ironclad Manufacturing partnered with ScaleUp to improve equipment effectiveness and reduce downtime across its global production network. Over ten months, the engagement delivered significant efficiency gains and stronger operational reliability.
This engagement is part of ScaleUp’s ongoing work helping manufacturers boost efficiency and reliability across global production networks.
Aging equipment and inconsistent maintenance limited output.
Unplanned outages disrupted production schedules.
Variability across plants limited standardization.
Maintenance teams lacked the tools for predictive planning.
Improve overall equipment effectiveness across plants
Reduce unplanned downtime and disruptions
Standardize maintenance and production processes
Build predictive maintenance capability
Create a scalable model for future plants
Assessed equipment performance and maintenance practices.
Standardized preventive maintenance across all plants.
Deployed sensors and analytics to predict equipment failures.
Trained plant teams on new maintenance protocols.
Built real-time visibility into OEE and downtime by plant.
Plant Performance Diagnostic
Standardized Maintenance Program
Predictive Maintenance System
OEE Dashboard
Operator Training Program
Continuous Improvement Playbook
Analyzed equipment performance and plant operations.
Defined the target maintenance model and roadmap.
Rolled out predictive maintenance and standard processes.
Piloted changes in priority plants before full rollout.
Scaled successfully and continuously optimized performance.
27%
Higher OEE
45%
Less Downtime
19%
Reduction in Maintenance Costs
24%
Increase in Production Throughput
10 Mo
Project Duration
ScaleUp helped us modernize our maintenance approach and unlock efficiency gains across every plant in our network.
Robert Chen
VP of Operations, Ironclad Manufacturing
Technology
3.5x
User Growth
40%
Lower Churn
5 Mo
Project Duration
Retail & E-commerce
28%
Increase in Profit
18%
Reduction in Costs
2.4x
ROI in 12 Months
Healthcare
38%
Shorter Wait Time
26%
Patient Satisfaction
7 Mo
Project Duration
