manufacturing
Operations
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Global 60+ Plant Capacity Balancing & Workload Re- Allocation

A multinational industrial equipment manufacturer operating 60+ production facilities across 4 continents, producing custom hydraulic pumps, valves, and heavy gearboxes.

Runs onNiyojan

overall increase in enterprise fleet capacity utilization: 18%overall increase in enterprise fleet capacity utilization
reduction in unplanned overtime costs by balancing workload: 75%reduction in unplanned overtime costs by balancing workload

How the work runs

The pressure that made this worth automating, the steps the system runs, and what came out the other side.

Pressure & Trigger Points

Primary manufacturing facilities in North America operated at 95% capacity overload while secondary plants in South America sat underutilized at 60% capacity.
Planners managed facility schedules in isolated spreadsheet silos, making cross-factory workload re-allocation slow and complex.
Overloaded plants incurred massive unplanned overtime costs while underutilized plants suffered idle labor overhead.

The run · 5 operational steps

Click any step to inspect telemetry signals, model reasoning, and governance gates.

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Enterprise 60+ Plant Command Cockpit

Niyojan unifies active order books, machine utilization rates, labor availability, and shipping logistics across all 60+ facilities into one live dashboard.

Input Signal:

Real-time operational telemetry & queue

Reasoning Pattern:

MCP grounded vector inference

Governance Gate:

Policy constrained with audit write-back

Verified Business Outcomes

18% overall increase in enterprise fleet capacity utilization across 60+ manufacturing plants.
75% reduction in unplanned overtime costs by balancing workload evenly across global facilities.
Accelerated global master planning cycle time from 10 days to 2 hours.

Capabilities this relies on

constraint solving
system connectors
forecasting
scenario simulation
workflow orchestration

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