Case Study: High-value Electronics Manufacturer achieves 400% reduction in unplanned downtime with SymphonyAI

Automated out-of-control action plans drives 400% in reduction of unplanned downtime

High-value Electronics Manufacturer was dealing with significant downtime caused by out-of-control process (OCAP) alerts that stopped production while operators and engineers manually investigated issues. The paper-based SOPs, manual tracking, and reliance on tribal knowledge made it difficult to respond quickly and consistently, hurting production rates, yield, productivity, and engineering efficiency.

SymphonyAI implemented the SymphonyAI Industrial Platform to automate the OCAP process end-to-end, integrating disparate data sources, standardizing procedures, and using self-directed workflows and track-and-trace capabilities to guide troubleshooting and capture root causes. Within four months, the company achieved a 400% reduction in unplanned downtime and an 80% reduction in OCAP false alarms, while improving productivity and freeing engineers to focus on root-cause improvements.