Confidential
Manufacturing
AI-Driven Automation and Cloud Scalability for a Modern Manufacturer
A large industrial manufacturing firm with global supply chains needed to improve production monitoring, automate reporting, and ensure system scalability. Their legacy ERP system was rigid and difficult to scale, integration between factory sensors and digital platforms was broken, and deploying updates across global plants took too long. They also lacked a unified data layer for analytics.

Technologies Used
Services Provided
Our Solution
Zabrizon deployed a full-stack modernization strategy tailored for industrial use. The first step involved lifting the ERP backend and production data lakes to AWS, establishing multi-region failover capabilities and isolating OT networks for improved security and resilience. We then introduced AI agents that analyzed IoT sensor data in real-time, enabling predictive maintenance and significantly reducing unexpected downtime. To facilitate seamless integration across factory systems, we developed a robust API layer that connected PLCs, inventory management tools, and predictive analytics platforms. Alongside this, we implemented a containerized microservices architecture with CI/CD pipelines spanning three continents, ensuring consistent, rapid deployments across global plants. Finally, we launched a lightweight SaaS application designed specifically for factory managers, offering real-time dashboards to monitor equipment health, production KPIs, and historical incident data.
Key Features Delivered
Predictive Maintenance AI
Real-time monitoring and failure prediction from sensor data
Real-time monitoring and failure prediction from sensor data Connected Factory APIs
Seamless data exchange between ERP, PLCs, and apps
Global DevOps Framework
Unified CI/CD strategy for plants across three continents
Measurable Results
Project Timeline
Infra Audit & Risk Analysis
Deliverables:
- (3 weeks) OT/IT network segregation planning
- Factory asset mapping
Cloud Migration & Edge Connectivity
Deliverables:
- ERP backend move to AWS
- MQTT & PLC integration setup
DevOps + API Layer
Deliverables:
- CI/CD setup for multi-region
- Unified API layer across tools
AI & SaaS Rollout
Deliverables:
- Train and deploy predictive models
- Launch factory dashboard SaaS
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