Intelligent Factory Pilot for real time visibility

Client background:

Client: A leading manufacturer and a market leader in the manufacturing of aluminum extrusion dies, tools, products and industrial packaging

Industry type: Discrete Manufacturing

Products or Services or Core Business: Food Packaging

Geography or Areas of operations: Middle East

Challenge:

1.  Manual method of production data collection leading to erroneous and high cost in full time equivalent (FTE).
2.  Hindrance in agile decision making due to no or delayed visibility of real-time data
3.  Inability to fulfill customers’ orders on demand due to lack of visibility of the available inventory
4.  Inability to influence customers’ purchasing decision with real-time “Available-To-Promise” (ATP) & “Capable-To-Promise” (CTP) dates to convert more sales quotes and proposals into orders.

Solution:

The solution comprised of Wipro’s IoT Platform-Looking Glass, combined with Multi-Protocol Gateway software stack (MPIOTG) that simplifies connecting to the machines or sensors by supporting multiple industrial protocols.

1.  We delivered an end-to-end IoT Solution that automatically identifies the number of QC ready finished goods by retrofitting sensors to their legacy Blow Moulding machine(s).
2.  Related stakeholders were provided access to dashboards, for real-time production monitoring, enabling visibility on the status of every work order and a live view of the production process.
3.  Upstream integration of production posting data to Oracle MES enabled a “paperless” factory setup

Business impact:

1.  Reduction in FTE and error-free data of production process and finished goods
2.  Real-time visibility on the production process for every work order, for all stakeholders and business functions
3.  Real-time visibility on Available-To-Promise (ATP)
4.  Ability to influence customers’ purchasing decision with real-time ATP & Capable-To-Promise (CTP) dates to convert more sales quotes and orders into proposals
5.  With continuous monitoring, a reduction in machine setup time - up to 42%
6.  Up to 16% improvement in Overall Equipment Efficiency (OEE), with real-time monitoring

"We are happy to drive the Client’s Smart Factory initiative and help them achieve unprecedented business benefits with our unique offering that leverages a combination of digital, domain and engineering expertise. Intelligent Factory is a strategic initiative from Wipro to help our clients reinvent themselves towards achieving an ambitious vision – ‘Factory of the Future’ using exponential technologies." – Sanjoy, Head of Digital, Manufacturing.