Have you ever been in that situation where your computer is acting weird, and you have no idea why—or how to fix it? You’re not alone. But the difference between an annoying computer mouse glitch and an unidentifiable issue in a manufacturing facility is that the latter can mean 25% of your revenue is inexplicably slipping through the cracks.
One of our manufacturing clients was dealing with exactly this scenario. They had two production facilities—identical in hardware, software, and setup—but one was running at half the speed of its twin. Despite their best efforts, their IT department was stumped.
When they called us in, we were able to diagnose the issue. And no, the machines weren’t just taking extra coffee breaks. Instead, we found a near-effortless fix that solved the problem, doubled production speed, and restored consistent revenue across operations.
Here’s how we helped.
Why Was One Factory Half as Fast as Its Twin?
The company operated two production facilities with matching configurations:
- Facility A: Running efficiently, meeting production targets.
- Facility B: Operating much slower, taking twice as long to complete the same tasks.
The usual troubleshooting steps—checking hardware, running system diagnostics, and evaluating the network—showed no obvious problems. Despite their efforts, the internal IT team couldn’t identify the issue. With production timelines halved and the internal team too busy to focus on troubleshooting the issue, they reached out to us for help.
Using IT Diagnostics to Improve Operational Efficiency
Using a tool called Microsoft ProcMon (Process Monitor), we analyzed the system in detail. ProcMon tracks system activities in real time, revealing everything from file operations to system processes.
We ran multiple ProMon traces, and what we found was that the system at Facility B was processing every task twice. Where Facility A executed a single instruction, Facility B repeated it unnecessarily, creating delays throughout production.
Once the issue was identified, we collaborated with the internal team to apply the necessary patch. Within a single day, Facility B’s performance matched Facility A’s, doubling the output (and revenue) of the plant.
Increasing Speed & Revenue Without Overhauling Systems
The fix delivered measurable results without interrupting the plant’s operations:
- Enhanced Efficiency: Processes ran as designed, with no redundant tasks slowing things down.
- Increased Production Speed: Facility B’s output doubled, closing the performance gap.
- Increased Revenue: Doubling production speed increased the product the factory could produce, leading to higher revenue.
- Minimal Disruption: The solution required near zero downtime, keeping operations on track.
This project not only solved an immediate problem but also set the stage for a stronger IT partnership with our team.
Manufacturing IT Services: Model Technology Solutions
As this case study shows, manufacturing companies face some of the highest stakes when it comes to IT running smoothly and securely. The trouble is, the engineering resources many businesses have don’t always match the demands of keeping systems optimized, secure, and compliant.
We understand the unique challenges manufacturing companies face in today’s highly technical and regulated world—navigating standards like CMMC 2.0, managing IoT devices and PLC controllers, and ensuring minimal downtime. That’s why we’ve dedicated ourselves to learning the intricacies of the manufacturing industry and delivering tailored solutions to their IT problems.
Here are a few ways we help manufacturing companies enhance their IT systems:
If your business is facing similar challenges—or trying to do the work of 20 engineers with two employees—we built our Co-Managed IT solutions for you. Learn how we can help round out and specialize your team to fill gaps, streamline systems, and increase revenue for less than the cost of a single full-time employee.
