Digital Transformation of Batch & Recipe based Manufacturing Industry » Vegam

Digital Transformation of Batch & Recipe based Manufacturing Industry » Vegam

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Case Study – Digital Transformation of Batch & Recipe based Manufacturing Industry

Customer Profile

Pioneer in Adhesive technologies
Headquartered in Europe with Annual revenue over 20 Billion USD
Well established IT Team and Infrastructure. Use of industry leading IT tools like SAP ERP, Azure cloud, DCS Systems, PLCs etc.
200 Manufacturing units spread across 60 Countries
Varying maturity (Manual Operations, Semi Automated and DCS Driven Operations)
1000’s of Raw Materials & 1000’s of Finished Goods (SKUs)
Market Segments Addressed
Automotive sector,
Metals sector,
Packaging & Consumer Goods
Electronics & Construction
Complex material handling needs
Multi phase, recipe based manufacturing processes
24/7 operations

The Problems

Corporate Level Challenges

Transparency over plant Operations
Real time performance dashboards
Local variations or missing standardization in processes
Lack of collaboration

Plant Level Challenges

Lack of transparency over value chain.
Visualize Loses in capacity, productivity and cost
End to end integrated digital system for execution control
Local demands and locally driven optimizations suffer due to rigid SAP constrains.

Solution

Centralized or Regional Implementation to digitize all operations of the plants.
Map work flows & SOPs to digital SOPs
Enable devices and tracking mechanisms (Mobile, Hand Held, Barcode Scanners)
Make operations Paper Less. Remove all paper based work-flows & transactions
Bring on Smart Sensors, IOT devices for enhanced monitoring

Integrated all Silo Systems & Data. Develop relation references between data
SAP or ERP
Quality Systems / LMS Systems
Warehouse Systems
PLC , DCS , Sensors
Enable KPIs, Dashboards, Value Stream Reports
Enable access to relation data using API’s. Open the data for any AI/ML engine.

Solution Benefits

Productivity Improvements

20% reduction in inventory losses
40% improvement in right first time
Improved warehouse accuracy
Enhanced OEE
Data driven decisions and Prescriptive manufacturing
Strict FEFO with real-time validation

Cycle time Reduction

Reduced receive cycle time with digitized and easy operations
Less error and reworks as manual entry is completely avoided
Reduced truck waiting time with seamless entry point assignment based on technology

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