Industrial
Global Manufacturer
320%
ROI in year one
Industry 4.0 transformation across 5 plants — 99.5% uptime, 70% fewer defects.
Read Case Study →Mergen integrates MES, SCADA, and ERP into a single operating picture, surfacing OEE, downtime, and cycle-time analytics across line, plant, and enterprise.
Explore Smart FactoryMergen unified three MES platforms onto a real-time OEE pipeline; line supervisors see deviations within 30 seconds of occurrence.
Mergen designs supplier collaboration portals, demand-sensing analytics, and integrated S&OP platforms, surfacing risk events the moment upstream data shifts.
Explore Supply ChainMergen rolled out a supplier portal across 1,800 vendors with EDI / API ingestion and a Mergen-built early-warning model.
Mergen combines sensor telemetry, historian data, and ML to flag asset degradation early, routing anticipatory tickets so the right technician arrives prepared.
Explore Predictive OpsPredictive models trained on 2 years of historian data flag bearing-wear and seal failures 14-30 days before they manifest.
Mergen modernises QMS and CAPA workflows with computer-vision inspection, automated SPC, and closed-loop CAPA, freeing quality engineers for root-cause work.
Explore Quality 4.0Mergen integrated TrackWise + ServiceNow + ML-based vision inspection on three high-volume lines.
Plant-Floor Savvy
Our consultants have walked plants from automotive to semiconductor to pharma. We know what a control engineer values, and what won't survive contact with the line.
Our Approach →OT/IT Bridge
We work with PLCs, historians, and SCADA layers, not just ERPs. Edge architectures respect plant networks and the Purdue model without constraining innovation.
OT/IT Capabilities →Multi-Cloud
Latency-sensitive workloads stay close to the line; analytics push to the cloud. We architect both, and the integrations between them, based on what each workload needs.
Cloud Strategy →Outcomes
Engagements scoped against OEE, defect rate, downtime cost, and inventory turns. Measurable and repeatable.
How We Measure →MANUFACTURING SUCCESS
Real results from automotive, industrial, life sciences, and process manufacturing — measured in OEE points, defect reduction, and downtime hours saved.
See All Manufacturing Stories →Global Manufacturer
ROI in year one
Industry 4.0 transformation across 5 plants — 99.5% uptime, 70% fewer defects.
Read Case Study →Industrial Components Group
working capital released
Supplier portal + demand sensing across 1,800 vendors and 12 forecasting models.
Read Case Study →Continuous-Process Plant
reduction in unplanned downtime
Predictive maintenance on bearings, seals, and pumps — $6M/yr in avoided emergencies.
Read Case Study →FDA-Regulated Device Maker
FDA audit pass rate
TrackWise + ServiceNow + computer-vision inspection across high-volume lines.
Read Case Study →Whether it's a smart-factory rollout, a supply-chain rebuild, or a predictive-maintenance pilot — let's design the path forward together.
Book a 30-minute call with a senior architect from our manufacturing practice.
We benchmark your line(s) against industry peers and identify the top three OEE levers.
See how peers have lifted OEE, cut defects, and modernized supply chains with Mergen.
From smart-factory pilot to enterprise rollout — we scope a fixed-outcome engagement in 48 hours.