Altizon
Contact us

Dover Corporation: Eliminating production bottlenecks for a 12% OEE gain

Replacing information silos with a unified digital operations layer to deliver real-time visibility, condition-based maintenance and digital quality control across the enterprise.

Altizon’s impact

12%

average OEE uplift

17 plants

plants unified

300+

machines connected

The Challenge: Standardizing production performance across 17 global plants

Diverse machines, product types, and operating standards across 17 plants prevented a standardized OEE and Quality baseline, forcing Dover to rely on inconsistent, manual reporting across global operations

Limited production visibility
Isolated data sources: Production, downtime, and performance data were locked within PLCs, SCADA systems, and spreadsheets at individual plants.
Limited real-time insight: Supervisors lacked live visibility into line performance, delaying corrective actions.
Inconsistent benchmarking: OEE definitions and downtime categorization varied by plant, making cross-site comparison unreliable.
Reactive maintenance practices
Calendar-driven PMs: Preventive maintenance followed fixed schedules rather than actual equipment condition.
Limited failure pattern visibility: MTBF and MTTR trends were not systematically analyzed across assets and plants.
High unplanned downtime risk: Early warning signs of machine stress often went unnoticed until breakdowns occurred.
Paper-driven quality workflows
Manual quality checks: In-process inspections and compliance checks were recorded on paper or entered post-shift.
Delayed deviation detection: Quality issues surfaced after production, increasing rework and response time.
Audit preparation overhead: Retrieving historical records for audits required significant manual effort.

Dover needed a standardized digital foundation—one that could connect machines, people, and processes across plants while remaining simple for operators on the plant floor.

The solution: A unified digital factory across Dover’s global operations

Altizon deployed its Digital Factory Platform to create a single manufacturing data layer, integrating real-time machine data with productivity, maintenance, quality, and compliance workflows across Dover’s global operations.

Productivity and OEE visibility
  • Real-time OEE dashboards tracked availability, performance, and quality by line and shift.
  • Automated downtime tagging reduced manual errors at the source.
  • Hourly KPIs enabled structured daily performance reviews.
  • Labor and process efficiency metrics supported throughput optimization.
Outcome:
  • Operators and supervisors gained live visibility into losses, enabling faster corrective action and more accurate OEE tracking across plants.
  • Preventive maintenance schedules and digital work orders replaced manual planning.
  • Predictive maintenance models used live data from CNCs and test benches.
  • MTBF and MTTR analytics supported root-cause analysis.
  • Complete asset and spare-part histories improved readiness.
Outcome:
  • Maintenance shifted from calendar-based planning to condition-driven execution, reducing unexpected failures and shortening repair cycles.
  • In-process quality checks surfaced deviations in real time.
  • SPC was applied to critical parameters.
  • Root cause analysis connected production and quality data.
  • Digital QA forms replaced paper-based documentation.
Outcome:
  • Quality teams moved from retrospective reporting to proactive control, enabling faster response and audit-ready traceability.
  • Shift logbooks, EHS, and compliance checklists were digitized.
  • Standard templates improved consistency across plants.
  • Automated alerts flagged anomalies early.
  • Records became instantly retrievable for audits.
Outcome:
  • Standardized digital routines reduced compliance risk and improved operational discipline across plants.
  • Bi-directional integration with Dover’s ERP system synchronized master data.
  • Consistent definitions for products, assets, lines, and shifts.
  • Production and maintenance records aligned automatically.
Outcome:
  • A single source of truth replaced manual consolidation, enabling faster planning and cleaner cross-plant reporting.

The transformation: From manual to digital

Before Altizon
After Altizon
Outcome
OEE improvement
OEE varied widely across plants, with limited visibility into losses and performance drivers
Standardized OEE tracking across connected lines with real-time visibility.
12% average OEE uplift across connected lines
Order fulfillment
Limited enterprise-wide visibility constrained accurate capacity planning and delivery commitments
Cross-plant performance visibility enabled better planning and coordination
Minimized WIP inventory by aligning real-time production capacity with demand.
Downtime analysis
Downtime reasons were inconsistently captured across plants, limiting loss analysis
Standardized downtime taxonomy enabled consistent loss tracking across sites
Accurate downtime and loss analysis
Maintenance efficiency
Preventive maintenance followed calendar-based schedules with reactive breakdown response
Predictive alerts and condition-driven maintenance reduced unexpected failures
Reduced unplanned downtime through predictive alerts
Quality assurance
Manual quality checks and delayed deviation detection increased response times
Real-time quality monitoring enabled faster deviation identification and action
Faster deviation response and audit-ready traceability
Sustainability
Heavy reliance on paper-based logs and manual documentation
Digital workflows replaced paper-based routines across plants
Significant reduction in paper through digital workflows

More success stories like this

Pernod Ricard: Scaling operational intelligence across 30 facilities

Pernod Ricard: Scaling operational intelligence across 30 facilities

Altizon’s Digital Factory Platform unified Pernod Ricard’s production, quality, and sustainability data by replacing fragmented, paper-based tracking, creating a connected…

Read more
Varun Beverages: Standardizing performance across multi-OEM bottling lines

Varun Beverages: Standardizing performance across multi-OEM bottling lines

Altizon’s Digital Factory Platform helped Varun Beverages connect multi-OEM bottling lines and utilities into a single, vendor-neutral digital layer, replacing…

Read more
JK Tyre: Driving production intelligence across tyre manufacturing

JK Tyre: Driving production intelligence across tyre manufacturing

Altizon’s Digital Factory Platform helped JK Tyre unify critical shop-floor data across mixing, calendering, and cutting operations, replacing fragmented MES…

Read more

Build a data-driven manufacturing foundation across plants.

Book a 20-minute demo