Tyson Foods
1950s plant. $400 sensors + edge. One line → 35% less downtime, 25% OEE gain. Scaled to 50 plants.
Nestlé
40-yr-old factories. SAP S/4HANA + cobots + floor shifts. 30% less downtime, 40% faster inventory, 2,000 sites done.
P&G
1980s lines. Digital twins + IIoT. 50% fewer defects, scaled to 100 plants.
MacDon
1970s chaos. Edge APIs to dealer portal. 60% faster claims, 35% happier dealers.
Paglieri
1960s soap line. IIoT + RPA. Changeover 4 h → 45 min, 28% OEE gain.
Building on the principles from my earlier post—starting small, prioritizing integration over replacement, and empowering frontline teams—let's dive into actual success stories.
These case studies, drawn from recent implementations (2023–2025), show how legacy-heavy manufacturers turned pain points into competitive edges.
I've focused on factories with decades-old equipment, where "transformation" meant bridging the old with the new, not a full teardown.
Each highlights key tactics, results, and takeaways that align with the 70/20/10 rule and cultural shifts I mentioned.
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