Case Study – Digital Transformation of Batch & Recipe based Manufacturing Industry
Customer Profile
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Pioneer in Adhesive technologies
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Headquartered in Europe with Annual revenue over 20 Billion USD
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Well established IT Team and Infrastructure. Use of industry leading IT tools like SAP ERP, Azure cloud, DCS Systems, PLCs etc.
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200 Manufacturing units spread across 60 Countries
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Varying maturity (Manual Operations, Semi Automated and DCS Driven Operations)
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1000’s of Raw Materials & 1000’s of Finished Goods (SKUs)
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Market Segments Addressed
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Automotive sector,
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Metals sector,
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Packaging & Consumer Goods
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Electronics & Construction
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Complex material handling needs
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Multi phase, recipe based manufacturing processes
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24/7 operations
The Problems
Corporate Level Challenges
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Transparency over plant Operations
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Real time performance dashboards
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Local variations or missing standardization in processes
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Lack of collaboration
Plant Level Challenges
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Lack of transparency over value chain.
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Visualize Loses in capacity, productivity and cost
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End to end integrated digital system for execution control
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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
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Centralized or Regional Implementation to digitize all operations of the plants.
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Map work flows & SOPs to digital SOPs
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Enable devices and tracking mechanisms (Mobile, Hand Held, Barcode Scanners)
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Make operations Paper Less. Remove all paper based work-flows & transactions
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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
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Integrated all Silo Systems & Data. Develop relation references between data
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SAP or ERP
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Quality Systems / LMS Systems
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Warehouse Systems
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PLC , DCS , Sensors
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Enable KPIs, Dashboards, Value Stream Reports
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Enable access to relation data using API’s. Open the data for any AI/ML engine.
Solution Benefits
Productivity Improvements
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20% reduction in inventory losses
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40% improvement in right first time
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Improved warehouse accuracy
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Enhanced OEE
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Data driven decisions and Prescriptive manufacturing
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Strict FEFO with real-time validation
Cycle time Reduction
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Reduced receive cycle time with digitized and easy operations
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Less error and reworks as manual entry is completely avoided
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Reduced truck waiting time with seamless entry point assignment based on technology
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