A leading global glass manufacturing company
Industry: Manufacturing/Consumer Durables
Region :
The client a leading manufacturer of glasses, faced a growing need to modernize its production processes as its products became more advanced. Rather than opting for incremental improvements, the company set its sights on a bold transformation, aiming to create a cutting-edge smart factory that would revolutionize its operations and set new industry standards. Despite having large-scale production lines, the company relied heavily on manual processes, limiting efficiency and innovation
Challenges
The client had a few challenges ahead to get the desired results. But, it was a brainstorming session for the company’s top-up management to identify core issues. As per AGM, the manufacturer decided to hire Elaron as its AI- management consultant. Elaron had noted the below challenges to work on.
- Limited Automation: The client had large production lines but used minimal automation, which limited efficiency and performance visibility.
- Desire for Industry Leadership: The client aimed to pioneer a state-of-the-art, digitized factory that would serve as a model for the industry, setting new standards for smart manufacturing.
- Need for Digital Transformation: The client wanted to shift from workflow-driven to data-driven manufacturing to enhance efficiency, and product quality, and create connected products.
- Aggressive Timeline: The challenge included building a new smart manufacturing unit on a fast timeline to accelerate the company’s digitization.
The Solution
- Solution: Collaboration with Elaron: The client partnered with Elaron to create a technology foundation integrating advanced Industry 4.0 technologies.
Outcome: Increased Efficiency: Automation improved production efficiency by 11%, and real-time data access reduced manual tasks, freeing workers to focus on higher-value activities.
- Solution: Integrated Systems: A new technology layer was built to integrate data between shop floor machinery and company systems (e.g., SAP ERP), enabling seamless communication.
Outcome: Reuse of Integration Messages: The integration of IoT and automated processes led to smoother operations, ensuring materials and production information were always available, improving overall plant performance. The solution standardized machine integration messages, allowing the client to reuse these as building blocks for future projects, improving scalability.
- Solution: Automation of Supply Chain: Approximately 76% of the client’s supply chain processes were automated, and autonomous vehicle systems were introduced to improve material delivery to workers like Rajesh, enhancing safety and efficiency.
Outcome: Enhanced Worker Experience: User-friendly dashboards displaying real-time data from systems and shop floor machines were created to help workers and managers make informed decisions instantly. Workers like Sachin and Rajesh experienced improved productivity, safety, and empowerment by using tablets to access real-time data, request materials, and monitor production progress.
Results After implementing these innovative solutions, the client saw the following intriguing results:
Enhanced Efficiency Automation and streamlined data access increased production efficiency by 11%, while reducing manual tasks allowed workers to focus on high-value activities, boosting productivity.
Improved Plant Performance Integrating IoT and SAP ERP enabled smoother operations with 76% of supply chain processes automated, ensuring continuous material availability and optimized production flow.
Cost Savings Automation of low-value tasks led to an 11% reduction in operational costs, while optimized capacity utilization further lowered expenses.
Higher Product Quality Shifting focus to high-value tasks improved product quality, contributing to an 18% increase in profitability through more refined output.
Recognition as an Industry Leader The facility gained international acclaim as part of the World Economic Forum’s Lighthouse Network, establishing it as one of India’s top innovative factories.
Scalability for Future Expansion Standardized machine integration messages allowed the client to expand the solution across other plants, improving scalability by 30% and facilitating easier deployment in future projects.
Conclusion
The client’s successful digital transformation, driven by its collaboration with Elaron has revolutionized its core manufacturing capabilities, resulting in significant improvements in efficiency, product quality, and operational excellence. By embracing cutting-edge technologies.
The client has solidified its position as a leader in smart manufacturing and automation. With scalable solutions in place, the company is well-positioned for future growth, allowing it to continuously innovate and expand while maintaining high efficiency and delivering superior products to customers at an accelerated pace.