Digital Assistance System Delivers Sustainable Efficiency Gains
A leading German pharmaceutical and agricultural company, known for its pioneering work in R&D, is now setting new benchmarks in digital transformation and production optimization. To remain competitive and meet growing market demands, the company has embraced intelligent technologies that significantly boost production efficiency, reduce machine downtime, and enhance workplace quality and collaboration.
Among the most impactful innovations is MADDOX, the AI-powered assistance system from Peerox. It not only elevates production processes to a new level but also fosters a motivating, cooperative work environment through improved knowledge accessibility and structured daily routines.
Identifying Common Problems – and Boosting OEE
In today’s manufacturing landscape, production and technical managers face a common challenge: how to identify and minimize waste to increase Overall Equipment Effectiveness (OEE).
A detailed process analysis at a top-tier pharma site uncovered industry-wide pain points:
- Inefficient workflows and errors causing delays and quality losses
- Low employee engagement and motivation impacting team performance
- Poor information flow between departments and machines
- All these factors reduce the production efficiency and competitiveness of the facility. The company decided to take action – with Peerox.
Real-Time Support with MADDOX – Reduce Machine Downtime Fast
Whenever a connected machine experiences an issue, MADDOX instantly displays relevant knowledge entries from experienced workers on touchscreen displays and tablets directly at the line. Thanks to its direct connection to the machine data points, the system can identify the specific context of the disturbance and suggest tailored solutions. Most faults can be quickly resolved at the root cause – a key factor in minimizing machine downtime and increasing OEE.
One tap provides feedback to MADDOX’s AI-driven software, enabling it to continuously learn which machine data patterns correspond to which types of failures and successful resolutions. This tight integration with live machine data ensures that the software can recognize recurring issues and improve its recommendations over time.
If a malfunction lasts longer than 5 minutes, MADDOX prompts the operator to generate a standardized SAP notification – with just five clicks and no paperwork. The system autofills 25 SAP fields, while another 20 values are automatically sourced from connected machine data and internal systems.
This seamless integration between MADDOX, machine-level data, and IT infrastructure is only possible through close cooperation and a comprehensive transformation process – supported by the Peerox team.
Smart System Integration – and a Strong Partnership
Providing data in the required quality was a major practical challenge and a cross-functional task within the company’s overall digitalization strategy. In some cases, machine data interfaces were incomplete or incorrectly documented, load and latency issues occurred, and internal machine states had to be mapped to OEE-relevant statuses (e.g., PackML standard).
This integration into the complex data and IT landscape was significantly driven by the integration experts at Peerox. They coordinated with six different machine manufacturers as well as a globally active external IT service provider, thereby greatly relieving the project managers and on-site technical teams.
As a result, MADDOX is now deployed as a distributed server application within a complex network architecture consisting of four partitions – from the PLC to the cloud server – and captures more than 26,000 variables from over 50 production machines via monitored, fault-tolerant data interfaces.
In addition to being used for internal AI training, MADDOX also provides this data to other applications within the IT infrastructure (e.g., production dashboards).
Change Needs Support – Building Trust in New Technology
Even though MADDOX was designed with users in mind, its introduction was met with some hesitation. Many employees were unsure about sharing their personal experience-based knowledge with an AI system.
To support the rollout, Peerox developed a tailored onboarding program. Over 200 employees were trained using realistic production scenarios – both in virtual environments and at a dedicated training station with a fully functional MADDOX setup.
Regular support sessions, either on-site or online, helped address questions, reduce concerns, and adapt the system based on user feedback. Collaboration with local teams and internal trainers played a key role in creating a long-term, positive knowledge-sharing culture.
Proven Impact – 7% More OEE on a Critical Pharma Line
On a highly specialized pharmaceutical line with strict quality requirements, MADDOX delivered measurable success: OEE increased by 7%. This was achieved not just by reducing machine downtime, but also by improving communication across departments, minimizing scrap, and accelerating onboarding – especially valuable during recent organizational changes.
MADDOX’s intelligent root cause identification extended machine uptime and reduced production costs, clearly demonstrating its value.
The Future of Smart Production Starts Here
If you’re looking to optimize your production processes, reduce downtime, and empower your team with smarter tools, MADDOX by Peerox could be the solution. This AI-driven software not only streamlines workflows and cuts costs, but also delivers context-aware knowledge management exactly when it’s needed.
With MADDOX, you unlock the full potential of digital transformation and lay the foundation for a smarter, more efficient production future.
You can request your personal demo and experience MADDOX directly with our founders.