Connected Factory Solution Rollout for an IP Manufacturer across 150+ Factories

Client’s Requirement: A global industrial products manufacturer wanted to digitalize how they collect and monitor their assets and process data to ensure quality defects in manufactured products were effectively, authentically, and quickly traced back to the right source during the manufacturing process. There were other challenges in their digitalization journey related to variety in data sources, production processes and systems integration, shop-floor connectivity and asset mix, which had to be addressed comprehensively through a standardized approach to make it successful across their multiple global facilities. L&T Technology Services (LTTS), with its domain expertise and delivery experience, was the preferred partner to execute this global project covering over 150 plants. 

The LTTS Approach: Based on the complexity of the requirements and deployment scenarios, LTTS adopted a complete remote execution approach delivering a standardized yet flexible Define-to Deploy solution with following highlights:

• Machine Connectivity – By leveraging LTTS’ Machine Connectivity Framework, the project team was able to address the challenges of working with multiple control systems for asset connectivity.
• Product Traceability – Identified distinct manufacturing processes into standard templates to collect tailored data.
• Golden Batch – Defined Golden Product Batch criterion using analytics across factors such as raw material usage, quality, process yield and energy consumption.
• Energy Management – By leveraging LTTS’ award-winning solution, the project team was able to connect to multiple control systems across plants and bring visibility to all significant energy sources and consumption patterns and enable customers to start tracking and meeting their GHG emissions and sustainability goals.

Key Achievements: LTTS was successful in developing and deploying Connected Factory Solutions across the customer’s factories globally helping them achieve: 

• Automated, digitized, paperless data collection for efficient operations – 11 percent operation cost savings per factory each year.
• Energy savings and net zero goals – 4 percent of energy savings and 300+ MT CO2 reduction per factory each year.

With proven testimonials received from the customer, LTTS continues its long-term engagement as a partner of choice for the IP manufacturer.