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The challenge

A diversified industrial manufacturer ran 5 plants across 3 continents, each with its own MES, SCADA stack, and CMMS. The CIO had a target: 4 percentage-point improvement in OEE within 12 months. The CFO had a constraint: no operational outage during cutover.

What we built

Mergen consolidated three MES platforms onto a single ServiceNow ITOM instance with discovery, service mapping, and event correlation across hybrid plant-floor + IT estate. Real-time OEE dashboards surface line-level deviations within 30 seconds. Predictive maintenance models trained on 2 years of historian data flag bearing-wear and seal failures 14-30 days before they manifest.

Architecture highlights

The outcomes

Quote from the CIO

“Mergen showed us working software in our actual plant environment by the end of week 4. That’s when we knew this would land differently from any consulting program we’d run before.”

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