Catastrophic Factory Disruption & Multi Site Work Order Resequencing
A major industrial valve and actuator manufacturer with 5 plants, experiencing a major structural fire at Plant 2 that disabled the main heat treatment and machining bay for 60 days.
Run on Sankalp · Production Planning & Scheduling
The challenge
Plant 2 had 320 open customer work orders worth $42M in progress, representing 40% of the company quarterly revenue commitments.
Operations teams were overwhelmed, spending 5 days manually sorting through paper travelers to identify stranded job stages.
Competitors prepared to capture market share if customer orders were canceled or delayed by months.
How Sankalp solves it
Instant Facility Lockout & WIP Inventory Auditing
Sankalp registers the full facility outage and audits the status and completion percentage of all 320 active work orders.
Cross Plant Capability Matching
Scans open machine capacity and tooling compatibility across the remaining 4 operational plants in real time.
Automated Work Order Splitting & Redistribution
Splits complex multi stage jobs, routing unfinished rough castings to Plant 3 for heat treatment and Plant 4 for 5 axis machining.
Expedited Material Logistics Scheduling
Coordinates emergency inter facility trucking schedules to transport semi finished WIP inventory between facilities.
Real Time Customer SLA Communication
Generates updated, reliable delivery commit dates for sales teams to share with major industrial clients.
The outcome
- stranded production orders successfully completed and delivered
- 0%stranded production orders successfully completed and delivered
- complete multi plant disaster recovery replanning executed
- 0 hourscomplete multi plant disaster recovery replanning executed
91% of stranded production orders successfully completed and delivered within revised customer SLA windows.
Complete multi plant disaster recovery replanning executed in 4 hours rather than weeks of manual coordination.
Retained 100% of top tier customer accounts despite a catastrophic 60 day single plant outage.
Representative scenario: a modelled industry situation showing how this accelerator applies. Figures are projections, not a named client result.
Capabilities used
Every accelerator is assembled from the same capability layer, so a workflow you adopt here shares its foundation with the rest of the portfolio.
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