Process bottlenecks had led to significant delivery delays and cost overruns at the Singapore MRO plant of a leading aerospace manufacturing company with global service operations.
The client chose Infosys as their partner to address the challenges of delayed production, high costs and low productivity. Infosys’ initial assessment enabled an end-to-end connected factory solution, from selecting the right sensors to ensuring the right data elements were available for downstream intervention.
Key Challenges
- Old machines, brownfield plant, machines were not connected and did not have appropriate data
- Collecting data from unconnected and old legacy machines – lack of clear visibility of machine availability and performance as these followed the traditional process of manual quality inspection and maintenance tracking
- Dynamic demand and inefficient repair planning, caused by lack of machine visibility and operator utilization, resulting in the inability to ramp up production and a large backlog of orders
- Disintegrated energy and waste management systems
- Lack of traceability of WIP products and inefficient material management in warehouses
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The Solution
Infosys delivered a connected factory solution
OEE and condition monitoring for shop floor machines
- Assessment and installation of sensors for condition monitoring
- Wireless technology for shop floor integration solution
- Implementation of Dassault’s Apriso MES for production execution, quality and condition monitoring
Production cost optimization through intelligent scheduling
- Dassault ORTEMS was integrated with Apriso manufacturing execution systems and ERP systems to enable optimal scheduling by identifying and removing machine, labor and material bottlenecks
Energy and Waste Management
- Sensors and power meters were installed for tracking solid/liquid waste and power
- Integration of BMS systems
- Moved waste systems into Apriso for real-time correlation with production
Transformation of brownfield plant with retrofitting and customized solution
- Process bottleneck and machine maturity study
- Business KPI assessment and baseline
- Sensors and wireless evaluation
- Identified pilot cell for implementation
- Solution and roadmap recommendation
Benefits
Enabled schedule adherence and cost optimization
Production visibility increased from 2 days to 21 days
Customer delivery adherence increased by 5% in the first six months
Operational effectiveness efficiency (OEE) increased from 57% to 70%
Reduced revenue hours per par, from 0.80 hours to 0.75 hours, in the first 12 months
~10% decrease in solid and liquid waste from machines
