KEY CHALLENGES

Frequent Machine Breakdowns High manufacturing costs Lower OEE Wastages Equipment availability Employee Safety Quality/Defects Employee Satisfaction Inventory Management

Strengths W Weaknesses Proposed solutions and roadmap

• Global presence • Lack of IT-OT integration Connected Shop Floor Connected Manufacturing
• High brand value • Lack of data-driven decisions Up to 8% Up to 5% Up to 5%
OEE Up to 10% Wastages Profits Yield Up to 10% Inventory Up To 15% Efficiency
• Strong Financials S • Physical server infrastructure
• Real time tracking of production line data to monitor the planned
• Automated Guiding Vehicles (AGVs), & robots for loading, sorting,
Threats Opportunities production levels and hence reduce wastage
packing & stocking, and automated transporting and conveyor systems
• Pandemics disrupt operations • Monitor the quality and material consumption efficiency
O • Leverage real time data to make data • IIoT devices and sensors collecting data from humans and machines in
• Poor demand forecasting • Leverage real-time data to ensure JIT raw material delivery and avoid
driven decisions real time to provide insights and ensure safety
• Lack of industry trends & • Early adopters of Industry 4.0 situations of stock-outs or excess inventory near the production line
• IT-OT Integration integrates information technology (IT) systems used
customer experience • Big Data Analytics would drive IIoT systems to take information-driven
T solutions to digitize entire SC for data-centric computing with operational technology (OT)
integration leads to high • Install Cloud Servers to integrate real decisions based on real-time data
• Factory Asset Tracking and Monitoring using sensors, active RFID and • Co-bots intended for direct human robot interaction within a shared
obsolete inventory & write-offs time data across all geographies
Inventory dashboard space
Connected Maintenance Connected HSE
Machine Worker Fatalities &
Up to 10% Breakdowns Up to 5% Productivity 45% MTTR Up to 8% OEE 50% Up to 7% Productivity
Injuries
• Data driven maintenance alerts and regular maintenance schedule • Smart Energy saving systems to optimize power consumption
creation to ensure continuous operations by mitigating unplanned • Big Data Analytics to track optimum performance cycle
machine downtimes/failures • 3D work Instructions, Manuals, learning videos, etc, provides more
• KPI benchmarking and Quick RCA analysis for the breakdown and insight in-context on-the-job training
generation to avoid similar situations in future • Connected Worker: PPE kits can be connected to factory systems via
• Optical Guides Used to check dimensions of the final product IIoT – sensors tracking basic wellbeing and worker’s movement
• Device History Record (DHR) helps to track machine health & its usage • Smart Training & Onboarding using AR/VR – more effective, better
• Big Data Analytics to provide insights on quality of product & equipment talent retention, engaging
Financial insights

Sources:https://www.zdnet.com; https://www.researchgate.net; https://www.mudamasters.com; https://www.leanproduction.com/tpm.html; Google