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

  • Warehouse
  • Quality
  • Staging / Kitting
  • Staging / KittinManufacturing (Continuous, Batch Discrete)
  • Maintenance
  • KPIs, Dashboards & OEE Analysis
  • Labelling 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
  • Integrate all Data Sources
  • Unified Data structure
  • Real-time visualization
  • Simulation
  • Performance & Outcome prediction
  • AI/ML with Big Data
  • 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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