TLDR: THE BIG TAKEAWAY
Our AI Workforce solution enabled a $450M custom orders business to replace 29 employees with specialized AI workers, delivering $3.955M in total annual savings and 77% workforce reduction.
This implementation allowed the manufacturer to increase their daily processing capacity 143% while maintaining rigorous industry compliance, demonstrating that even the most complex tribal knowledge can be successfully digitized at scale.
Client Profile
This $2.3B global component manufacturer operates across North America, Europe, and Asia-Pacific with 8,500 employees worldwide.
Their custom orders business generates $450M annually by producing engineered components for industrial applications, processing more than 12,000 specialized orders each year. The company’s most profitable segment was constrained by manual BOM processing that required senior engineers to interpret complex customer specifications.
A $2.3B component manufacturer faced a critical bottleneck in their most profitable business line. Their custom orders operation required a dedicated workforce of 31 employees—23 senior engineers, 6 quality assurance reviewers, and 2 training specialists—to manually convert customer specifications into structured Bills of Materials, a process that had become unsustainable.
Operational Challenges
The human workforce problems:
- 31 employees costing $4.1M annually for sophisticated data entry and review work
- 4.2 hours per order processing time creating customer delays
- 78% first-pass accuracy requiring expensive rework
- Peak season capacity constraints limiting revenue growth
- Knowledge locked in human minds creating business risk
Previous automation attempts had failed. Traditional RPA couldn’t handle format variability, rules-based systems worked for only 15% of orders, and offshore processing resulted in 40% rework rates.
The breaking point: During peak seasons, the team could only process 35 orders per day, leaving hundreds of customers waiting and millions in revenue at risk.
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