Shareholders want faster green-field factory setup, better margins instead of 6-9 month lags in the era of digital-led manufacturing

Ankur Jain

7 days ago

2 min read

A major automotive ancillary is in the process of setting up a new green-field plant across two phases. The major question that pops up each time a new setup happens is how sonner the factory starts to payback the shareholders.

This is the same question that has come up again for an auto-ancillary major. My answer below is for the CIO stakeholders as I am a digital transformation analyst and my answer talks about how digital transformation can better pace your plant setup

Digital Twins help you to commission faster by reducing the number of physical trials and errors that your plant managers need to undertake
Stabilize quality sonner instead of waiting for it to reach optimal level in 6 months. Real-time monitoring of machines help you in comparative machine analysis and optimization
Use dashboards to monitor your machine metrics instead of relying on what numbers come at end of week. This will help you in finding bottle-necks early
Replicate good performance across machines, this is quite similar to what I suggested in point 2 under comparative machine analysis
Identify abnormal equipment behaviour through pattern analysis. Manual divergences take 6 months to get caught

These 5 points have been implemented globally for manufacturers under fancy Industry 4.0 titles and terms.

Checkout the below flagship case-study :

Ryobi + Smart Manufacturing Data Hub

Joint team of two instituitions sat together to improve OEE at the plant level. To enable the same, they connected multiple machines together and found key insight

"Data revealed that one machine was 13% more energy-efficient and had 11% higher OEE than the other"

Along with this key insight, one more information is being provided

"What are the machine parameters that are being set and how they can be overlayed on the under-performing assets to ensure higher cost-effective utilization"

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