Global economic uncertainties and other domestic factors, such as rising inflation and currency depreciation have a profound influence on the manufacturing sector in India. As the Euro zone crisis evolves, global industrial companies, seeking growth opportunities outside their traditional markets, will foray into India, making it an intensely competitive marketplace. To be able to compete and survive in these tough economic conditions, operational excellence has become mandatory. Enabling technology solutions empower continuous improvements in critical areas, such as asset management, production efficiency, product quality, safety, sustainability, and supply chain efficiency. The Process Industry at large and especially the manufacturing companies in India must focus on continually enhancing their performance, efficiency, and competitiveness by focusing on asset performance with the help of business intelligence and asset-performance information solutions.
Recent studies conducted by ARC Advisory Group have identified poor Asset Information Management (AIM) as the root cause of many asset performance problems, such as poor asset utilization, low maintenance efficiency, high Maintenance, repair, and operations (MRO) costs, and others. ARC estimates the cost of poor AIM for a typical asset-intensive organization to be close 1.5 percent of sales revenues – a staggering burden for any company today. Poor AIM also increases the risk of safety, health, and environmental incidents, which can jeopardize an enterprise’s very survival.
While the opportunity for improvement is incredible, many organizations continue to suffer the pains of poor AIM. Some do not recognize the opportunity. Others understand that they have problems, but do not know how to solve them or cannot justify the required investments. The future belongs to those companies that can integrate and achieve collaboration to address asset performance problems. Leading IP-based products-led companies such as Rolta have designed solutions, like Rolta OneView™ Enterprise Suite, which provide comprehensive visibility and operational transparency across platforms and disparate systems.
Operational Excellence through Optimal Asset Performance
Manufacturing companies in India have to learn to succeed by competing with global companies, which enjoy numerous inherent advantages. Domestic industrial companies have to accept that in a flat world, competition among manufacturing companies is across-the-board and therefore not always among equals. These companies have to develop their growth approaches that include strategies to gain sustainable competitiveness so that they can compete and succeed. Global companies have a head start over their domestic counterparts. Over the years, they have built competencies by reducing energy costs and efficient deployment of all resources. They have moved away from low labor cost arbitrage and instead increased their investments in innovative technology solutions and deployed these for improving productivity, supply chain efficiencies, optimize the entire design-operate-maintain cycle, and such others. Global companies focused more on improving asset performance compared to investing in creating additional production capacities alone and pursued operational excellence for gaining competitive advantages. While domestic manufacturing companies have been grappling with millennial challenges and in building production capacities, global happenings increase the pressure on them by shortening the time they have to adjust and adapt to these new business norms.
The global economic turmoil, triggered by on-going crisis in Europe, profoundly influences India’s economy and the manufacturing industry. Moving forward, domestic manufacturing companies will encounter tough challenges in ensuring their top line growth and protecting their margins. As the crisis further unfolds, manufacturing companies in the developed economies will increasingly find India, which fortunately continues to remain a domestic demand centric economy, an attractive market. The excess production capacity, which these companies have, will find its way into India, making the country’s industrial landscape extremely competitive.
Domestic industrial companies, in order to emerge successful, will have to seek global competitiveness, perform better than all the others along the entire value chain starting from product conceptualization, engineering, plant operations and maintenance, and such others. Achieving product excellence, though important, is not enough for a company to emerge successful, but achieving excellence in all its operations is extremely crucial. Manufacturing companies must focus on continually enhancing the performance, efficiency, and competitiveness by focusing on asset performance with the help of business intelligence and asset-performance information solutions.
Align Business Goals with Asset Performance Optimization
Industrial companies have to focus on maximizing the proper utilization of all their assets - financial, human, fixed assets, and such others. Companies will have to align business goals with strategies relating to asset creation and utilization; track key performance metrics and generate actionable intelligence to all stakeholders across the enterprise for achieving operational excellence.
Manufacturing companies can enhance their organizational performance, efficiency, and competitiveness by optimizing asset performance with the help of business intelligence and asset information management solutions. These include technologies that integrate information across plant and corporate systems; manage information quality; facilitate understanding with graphs, 3D and geospatial visualization; and enable rapid detection and analysis of hidden opportunities and threats. Such asset information management solutions must extract and provide every stakeholder the full information they need to optimize their contributions and achieve operational excellence.
Rolta OneView™ – Helps in Asset Information and Performance Enhancement
Recently Dr. Bhot, Group Director, Enterprise IT Solutions Business Group, briefed ARC about Rolta OneView™. One of the major challenges in the industry is to improve operational performance without compromising safety, regulatory compliance, and corporate goals. Improving operational efficiency calls for accessing, collating, understanding, and analyzing the data from disparate sources and systems, and these pose major hurdles.
Rolta OneView™ has pre-built connectors to seamlessly capture in real-time, enterprise wide mission-critical information from various business functions and disparate sources, such as enterprise resource planning (ERP) and supply chain management (SCM); operations management sys-tems such as manufacturing execution systems (MES) or collaborative production management (CPM) systems; and plant automation systems, such as distributed control systems (DCS) and programmable logic controllers (PLC). It facilitates data assimilation, information synthesis, complex analysis, scenario modeling, simulation, forecasting and provides rich visualizations.
OneView™ Enterprise Suite helps to accomplish operational excellence with its ability to translate data into cross-functional KPIs and KPIs into actionable intelligence through data drill down and easy custom reporting. It supports initiatives such as Balanced Scorecards, Six Sigma, TQM, and others. Rolta OneView™, seamlessly integrating mission critical information emanating from various business functions, such as production, maintenance quality, and supply chain, provides actionable information relating to operations, assets, sustainability, health, safety, and such others to all stakeholders at all levels – from the top corporate level all the way down to operating engineers and supervisors.
Rolta OneView™, acting as a comprehensive integrated decision support system, provides actionable information and real time intelligence and thereby empowers manufacturing companies to enhance asset utilization. The solution set is scalable and has analytics and calculation engines. It can work with geospatial systems and has the capacity to display actionable information and key performance indicators on various dashboards. Rolta OneView™ is built to encourage knowledge management and a proactive culture; the convergence of these factors leads to customer satisfaction. Rolta OneView with significant amount of domain knowledge built into it is a ready-to-use enterprise suite.
Last Word
While India offers excellent growth opportunities for industrial companies, it is imperative for them to adopt strategies to enhance efficiency, performance, and competitiveness. This is achieved with the help of business intelligence and asset information management solutions. The recently introduced Rolta OneView™ solution gathers and provides cross-domain, actionable information. ARC believes that manufacturing companies aspiring to take advantage of the growth opportunities that the country offers and emerge as best-in-class must take the technology route to achieve operational excellence and enhance their asset performance.
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