One of the world’s largest chocolate manufacturer wanted to implement a digital manufacturing solution across multiple factories to improve operational efficiency and productivity. The company sought a service provider to maximize digitization and standardize the data. There was a lack of an integrated data hub with a single source of truth that consolidated data from the plant machines, operations, production process and other systems. Infosys implemented a data hub for 32 plants covering 112 manufacturing lines that are globally distributed. Infosys also developed a digital control tower that provides remote operations capability at a plant.
- Centralized data across different systems
- Visualized real-time and historical data for appropriate analysis
- Improved plant performance analysis and better decision making through consolidated dashboards for business KPIs
Key Challenges
- Absence of data standardization and KPIs across multiple lines and plants that led to inefficient analysis, reporting and corrective actions
- Need for data harmonization to synchronize people, equipment and products around the demand signal
- Gain visibility on constraints (products, assets, workforce and cost) of the plant and supply chain to ensure service reliability
- No provision for plant performance analysis necessitating operational, yield and quality historical data on shift, daily, monthly, quarterly and yearly basis
- Lack of scalability and provision to roll out to multiple plants and lines for collaboration across the enterprise
Ready to experience?
TALK TO EXPERTS
The Solution
Infosys implemented a digital control factory for plant operational data
- Real-time monitoring and control of equipment
- Centralized data repository and global solution to enable historical data reporting for multiple plants
- Data standardization - Standard and consistent KPI reporting across plants and the organization with a one-stop solution to perform quality and performance analysis
- Data analysis - Historical data comparison for multiple plants and lines were made available on shift, daily, weekly, monthly, quarterly and yearly basis
- Multi-system integration with plant-based quality systems and plant operational systems to enable a consolidated data view
Solution rolled out across 32 plants and 112 lines
- The solution, connects factory equipment data to the KPI platform built on PTC ThingWorx, uses PTC Kepware OPC for machine connectivity
- Centralized data storage on SAP MII (runs on NetWeaver cloud platform)
- Accessibility of persona-based reports on tablets, smartphones and as web applications
Benefits
20% reduction in SFG, solid and liquid packaging waste
12% increase in capacity utilization
6% reduction in unplanned downtime
5% increase in plant productivity
Faster decision making and higher product attainment through seamless system integration
Multi-language support
Comparative analysis of plants across the globe for better assessment and taking corrective measures
Improved transparency on operational performance enabling better decision making
