From Pilot to Production — Proven
Every engagement we take on is measured by one thing: measurable impact on your operations. Here's what that looks like in practice.
Tier-1 Supplier Cuts Unplanned Downtime by 43%
The Challenge
A leading Tier-1 automotive supplier producing transmission components was experiencing frequent unplanned equipment failures on critical CNC machining lines. Each hour of downtime cost approximately ₹12 lakh in lost production, and reactive maintenance was consuming 60% of the maintenance team's capacity.
Our Solution
PRAJYA deployed a production-grade predictive maintenance system integrating vibration, temperature, and acoustic sensors across 38 machines. Our AI models—trained on 18 months of historical failure data—predict failures 72 hours in advance with 91% accuracy, enabling planned maintenance windows during scheduled downtime.
"We went from firefighting every week to planning maintenance like clockwork. The ROI was visible within the first quarter."
— VP of Operations
Results
Unplanned Downtime
OEE Improvement
Time to Deploy
Precision Parts Manufacturer Reduces Defect Rate by 67%
The Challenge
A precision engineering firm supplying aerospace and defence components was struggling with a 4.2% end-of-line defect rate—three times the industry benchmark. Manual visual inspection was inconsistent, and rework costs were eroding margins on fixed-price contracts.
Our Solution
PRAJYA implemented a computer vision quality inspection system on four production lines. High-resolution cameras capture 120 images per minute; our deep learning models detect surface defects, dimensional deviations, and assembly errors in real time. Defects are flagged and routed for rework before reaching the next station.
"The system catches things the human eye simply cannot. Our customer rejection rate has dropped to near zero."
— Head of Quality Assurance
Results
Defect Rate
Rework Costs
Time to Deploy
Chemical Manufacturer Achieves 31% Inventory Cost Reduction
The Challenge
A mid-size specialty chemicals manufacturer was carrying excess raw material inventory worth ₹18 crore due to inaccurate demand forecasting. At the same time, stockouts on three key inputs were causing production stoppages twice a month, disrupting delivery commitments to key customers.
Our Solution
PRAJYA built an AI-powered supply chain intelligence platform that integrates ERP data, supplier lead times, commodity price signals, and customer order patterns. The system generates rolling 12-week demand forecasts with automated reorder recommendations, reducing both overstock and stockout scenarios simultaneously.
"We freed up over ₹5 crore in working capital in the first six months. That alone paid for the entire engagement."
— CFO
Results
Inventory Carrying Cost
Stockout Incidents
Time to Deploy
We use cookies
PRAJYA uses essential cookies to keep the site secure and functional. We do not use advertising or tracking cookies. By clicking Accept, you consent to our use of cookies as described in our Privacy Policy.