DoD Manufacturing Facility Achieves 99.2% Uptime

A Department of Defense manufacturing facility producing critical defense components across 50 production lines experienced 150+ unplanned downtime incidents annually. The facility's aging industrial control systems, some over 15 years old, lacked predictive maintenance capabilities and had significant cybersecurity vulnerabilities. Unplanned downtime disrupted mission-critical production schedules, threatened delivery commitments, and cost over $18 million annually in lost production and emergency repairs.

NexDyne Technology was awarded a contract through DoD's IDIQ vehicle to modernize the facility's cybersecurity posture, implement predictive maintenance analytics, and achieve CMMC Level 3 certification. The solution would eliminate unplanned downtime, provide real-time operational visibility, and ensure compliance with stringent defense cybersecurity requirements.

NexDyne Technology deployed FedRAMP-authorized cybersecurity platforms with zero-trust network architecture and continuous monitoring specifically designed for ICS/SCADA environments. The implementation included zero-trust network architecture with micro-segmentation, FedRAMP-authorized endpoint protection on all industrial control systems, and continuous monitoring with SIEM integration for real-time threat detection.

The team deployed IoT sensors across all 50 production lines with machine learning-powered predictive maintenance analytics. Over 2,500 IoT sensors were installed monitoring vibration, temperature, and pressure across critical equipment. The system achieved 94% accuracy in predicting equipment failures 72 hours in advance, enabling maintenance teams to schedule repairs during planned downtime rather than responding to emergency situations.

The comprehensive approach addressed both cybersecurity and operational efficiency simultaneously. Real-time dashboards provided facility leadership with complete visibility into equipment health, production status, and security posture. Automated alerting ensured rapid response to both emerging equipment issues and potential security threats.

The implementation delivered transformative results for the manufacturing facility. System uptime improved to 99.2%, with unplanned downtime incidents reduced by 75%—from 150+ annually to just 38. The 72-hour advance warning for equipment failures allowed maintenance to be scheduled during planned downtime, eliminating the emergency repairs that had previously disrupted production schedules.

Financial impact was substantial, with $12.5 million in annual savings achieved through reduced emergency repairs, improved production efficiency, and optimized maintenance scheduling. The facility successfully achieved CMMC Level 3 certification, meeting all stringent defense cybersecurity requirements and maintaining eligibility for defense contracts.

The facility director noted that the predictive maintenance platform transformed manufacturing operations, enabling the shift from reactive emergency response to proactive maintenance planning. The success has led to discussions about expanding the implementation to additional DoD manufacturing facilities, establishing a model for defense industrial base modernization.