Core AI Development Manufacturing

Global Manufacturing Supply Chain Optimization

Machine Learning for Predictive Intelligence

Client Profile

150+ facilities across 40 countries, managing 50,000+ SKUs with annual revenue exceeding $25 billion

Key Results & Impact

Forecast Accuracy

42% improvement (68% → 96.5%)

Annual Savings

$127M from reduced inventory costs

Stockout Reduction

89% reduction in incidents

Planning Cycle

Reduced from 3 weeks to 2 days

ROI

485% within 18 months

The Challenge

Critical supply chain inefficiencies resulting in $300M annual losses from stockouts, excess inventory, and suboptimal production scheduling. Legacy ERP systems couldn't handle the complexity of global demand forecasting with 2,000+ variables.

Our Solution

Built distributed ML pipeline on AWS SageMaker processing 2TB daily data with ensemble forecasting combining XGBoost, LSTM networks, and Prophet. Created feature engineering pipeline with 3,500+ features including weather data, economic indicators, and social media sentiment.

Technologies & Tools

AWS SageMaker XGBoost LSTM Prophet Apache Kafka Apache Spark MLflow Kubernetes

Technical Implementation

Architecture

Distributed ML pipeline on AWS SageMaker

Data Processing

Apache Kafka for real-time data ingestion (500K events/sec), Spark clusters for distributed preprocessing

ML Models

Hierarchical time series forecasting with reconciliation, Multi-objective optimization using genetic algorithms

Integration

REST APIs for ERP integration (SAP, Oracle), GraphQL for frontend applications

Business Impact

Transformed global supply chain operations with 42% improvement in forecast accuracy, $127M annual savings, and 485% ROI within 18 months.

Case Study Details

Industry: Manufacturing
Service: Machine Learning
Category: Core AI Development
Client: Fortune 500 manufacturing conglomerate

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