Manufacturing Case Studies

AI-Assisted CAD Validation

A Tier 1 automotive supplier partnered with Sphere to accelerate CAD/CAE validation using AI surrogate models and workflow integration with ANSYS/CATIA. The Proof of Concept reduced simulation runtimes from days to hours, enabled 3–4x more design iterations, and cut validation timelines by up to 40%—helping the client meet OEM program milestones and improve design agility.

Revolutionizing Operations: How Sphere’s NetSuite Integration Transformed Cirrus LED’s Efficiency and Growth

Located in Portsmouth, New Hampshire, Cirrus LED (Cirrus) engineers and manufacturers high-quality, cutting-edge modular display systems for outdoor digital signage using one of the most advanced robotic assembly lines in the world. They also install and service their products, so they have many different operational requirements.

NOC for Multinational Client — 50% Faster Time to Response with AI and Process Automation

NOC for multinational client achieves 50% faster time to response with AI and process automation

Custom AI Solution for Manufacturer

Since 2017, the firm’s US operation faced a significant change to its digital transformation strategy as they were acquired and needed to conform to the Corporate strategy.   They sought out external expertise to advise them on ways to use technology and IoT data to allow production leads to track and adjust the process as needed. They were looking for a proactive real-time approach to utilize their manufacturing and quality data to correct their manufacturing process deficiencies when a problem was detected. To implement this AI-based approach, our data consultant had to identify and analyze all the possible data sources during the manufacturing process and design a centralized data extraction, transformation, and load (ETL) process across the entire manufacturing system nodes.

Leading distributor of industrial products selects Sphere Partners to integrate their CRM with monday.com

Full service sales engineering firm sought a tech partner to help them integrate their CRM of choice (Epicor) to their Work OS, monday.com.

Multinational company closes its data centers and migrates custom solution to the cloud, improves TCO

A multinational company wanted to realize lower total cost of ownership for its product supporting infrastructure, and decided to shut down its on premise data centers and move all the operations and hosted solutions to Microsoft Azure hosted cloud platform.

Custom cloud migration provided scalability and improved performance

Our client migrated a custom solution with Oracle database to the cloud, leverages SQL Server Managed Instance and Azure Synapse platform.

How we helped our client gain more visibility into their production process using NetSuite

A large branded promotional products company was looking to bring visibility to their production process across the organization so at any point a representative would know the status of an order. They partnered with our NetSuite team to fulfill their development needs.

Revolutionizing Quality Control in Glass Fiber Manufacturing with AI

Implementing RPA in Consumer Electronics Manufacturing

Explore the journey of a leading global consumer durables and electronics manufacturer, employing over 31,000 individuals and dominating markets across the world. The client faced challenges due to shifts in consumer purchasing behavior and the need for advanced automation solutions. With Sphere's assistance, they implemented robotic process automation (RPA) to enhance error handling in e-commerce and marketplace orders, significantly boosting both internal and third-party system efficiency. The initiative not only improved operational resilience but also redirected the organization’s focus towards strategic and value-added activities.

Intelligent Automation to Streamline Operations

Computer Vision for Defect Detection

Despite employing manual quality inspections, subtle defects often went unnoticed, leading to product recalls, wasted materials, and rising operational costs. The client needed a reliable, cost-effective solution to: Ensure 100% quality coverage without slowing production. Minimize human error in quality control. Provide real-time insights to reduce waste and prevent costly rework. Our Computer Vision Quality Control system was tailored to solve these issues, helping the client not only detect defects but also optimize their production process for long-term efficiency.

AI-Powered Order Automation

A global medical device manufacturer processing over 50,000 B2B orders per month faced mounting inefficiencies from heavily manual order handling across fax, email, and portals. With 30+ staff dedicated to data entry and frequent delays caused by weekend backlogs, the company struggled to scale with rising demand. Sphere implemented an AI-powered order automation platform that transformed legacy workflows, dramatically cut labor costs, and unlocked sustainable growth—without expanding headcount.

AI-Powered Invoice Auditing

A leading order fulfillment company shipping over 500,000 packages annually with DHL and FedEx was losing hundreds of thousands in revenue due to undetected carrier billing errors and inefficient manual audits. With only 5% of invoices reviewed, most discrepancies went unnoticed. Sphere deployed an AI-powered invoice auditing system that automated validation at scale, eliminated manual workload, and recovered over $400K in just six months—turning a cost center into a high-impact profit driver.

Data Modernization for a Chemical Manufacturer

A global chemicals manufacturer partnered with Sphere to connect lab, plant, and supply chain operations. By consolidating LIMS, MES/SCADA, and ERP data into Snowflake, automating lab-to-plant recipe transfer, and applying predictive maintenance and demand forecasting models, the client achieved faster product scale-up, reduced downtime, and improved supply chain efficiency.