P&G deployed an IoT and predictive analytics system on Pampers diaper production lines that monitors real-time sensor data from glue stream equipment and predicts manufacturing failures hours in advance, enabling technicians to intervene before defective diapers are produced. The system was rolled out to approximately half of P&G's US Pampers manufacturing plants after a pilot.

P&G worked with Microsoft to deploy an IoT and edge analytics platform — using Azure IoT Hub, IoT Edge, sensors embedded in assembly line equipment, and a rules-based AI engine — to monitor the temperature and pressure of 40 hot glue streams critical to the Pampers manufacturing process. The AI engine continuously tests incoming sensor data against manufacturing specifications and can flag impending failures six to eight hours before they would occur, allowing preventive maintenance without stopping the line. The platform was pilot-tested for nine months at one plant and then rolled out to approximately half of P&G's US Pampers manufacturing plants. CIO.com (2022, updated 2025) confirmed P&G estimates the system eliminated 70% of flawed diapers that previously had to be scrapped, representing savings in the seven-figure weekly range. P&G's IT Senior Director of Global Baby Care Services confirmed the project was planned in late 2021.