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Long Term, Not Short Term

Long Term, Not Short Term

Unplanned Digital Journeys Lead To Inefficiencies, Limited Roi And Escalating Costs

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Goals Of Effective Manufacturing

Manufacturing Excellence
Manufacturing Excellence

Despite continuous data generation from the digital nodes, operators are still unable to use the data for actionable decisions and missing out on the opportunity of improving the business resilience.

OT-IT Convergence
OT-IT Convergence

Siloed systems are present across Planning, Production, Quality, Maintenance, Warehouse departments. Their integration with business-critical IT systems becomes critical for smooth operations.

Sustainability & Governance
Sustainability & Governance

Despite continuous data generation from the digital nodes, operators are still unable to use the data for actionable decisions and missing out on the opportunity of improving the business resilience.

Product Quality Supremacy
Product Quality Supremacy

Consistency required in quality product delivery to exceed ever changing customer demand while maintaining profitable growth.

Workforce Adaptability
Workforce Adaptability

Employees are unable to keep pace with the evolving advanced technologies. Moreover, current scenarios call for better remote operations.

Challenges Daunting the CPG Industry

CPG manufacturers are producing either commodity products driven by volume or luxury products at the other end, driven by margin. For both the categories, effective new product development, building supply chain effectiveness and cost control measures can help businesses improve their margin and maintain their cost-effectiveness. The current times have pushed companies to adopt and scale digital to build resilience and achieve operational efficiency. There has never been a greater impetus for integrating digital and physical systems to optimize and transform the existing factories into future-ready factories.

Challenges Daunting the CPG Industry

Digital as a Means to Enable Transformation

While each organization’s digital goals will be unique to their strategy and vision, understanding where they stand would enable businesses to define the digital roadmap effectively. Assessment of current digital maturity can help organizations to identify the gaps in their digital journey, benchmark against their industry peers and create an action plan with short-term and long-term objectives to achieve their business objectives.

Digital as a Means to Enable Transformation

One digital thread. One Mission.

C-Suite
Key KPIs

 

  • Explore New Business Model: Digital technologies to adapt evolving market dynamics with changing customer expectations and external factors to achieve sustainable growth.
  • Total Cost of Ownership: Digital investment, operating expenses And contribution margin by leveraging the existing infrastructure
  • Business Sustainability: Identify the business process to prioritize the digital initiatives

Plant Head
Key KPIs

 

  • Productivity: See that the plant is performing as per average throughput on a daily basis
  • Downtime: Monitor the downtime due to production changeover, emergency shutdown to maintain the productivity of the floor
  • Safety: Prevent workplace incidents/accidents
  • Overall Equipment Effectiveness (OEE): OEE helps about the overall performance of the factory
  • Quality: Ensure non-compliance in production is kept to the minimum

Engineering Head
Key KPIs

 

  • New Product Development (NPD): Accelerate the NPD process to meet changing market demands
  • Utility Monitoring: Optimized usage of key utilities like water, air, gas, electricity, steam
  • Quality: Ensure quality in Product and Process
  • Project Progress Performance: Track how well the project is progressing as per its plan
  • Asset Reliability: Ensure minimum unplanned breakdown so that plant assets perform to their optimum level

Focus Areas

Continual Transformation (Ctr)

Cluster Areas
  • Consulting Services
  • Predictive Analytics & Decision Support Services
  • Robotization Services
Benefits Delivered
  • Expert know-how, step-by-step implementation
  • Maximize plant availability, early fault detection
  • Improved working condition, operator enablement
Productivity
Inventory

Connected Value Chain (CVC)

Cluster Areas
  • Design & Manufacturing Engineering Services
  • Digital Threading & Twinning Services
  • Knowledge Threading & Management Service
Benefits Delivered
  • Shorter time to market, extended life-cycle
  • Easy access to product data, tailored learning
  • Next level productivity, engaged participation
Productivity
Warehousing Cost
Waste

Digital Assets & Security (DAS)

Cluster Areas
  • Asset Reliability Services
  • Digitization & Data Centricity Services
  • IT-OT Integration & OT Security Services
Benefits Delivered
  • Early fault detection, prolonged service life
  • Step-by-step digitalization, data driven analysis
  • Expert vulnerability and risk analysis
Productivity
Changeover
Waste

Intelligent Sustenance (INS)

Cluster Areas
  • Genealogy & Tracking Services
  • Migration & Support Services
  • Sustainability Services
Benefits Delivered
  • Improved quality, compliance monitoring
  • Application enhancement, time & cost optimization
  • Sustainable manufacturing, optimized energy cost
Energy Efficiency

Smart Manufacturing & Operations (SMO)

Cluster Areas
  • Automation Services
  • Operations Improvement Services
  • Visibility & Dashboarding Services
Benefits Delivered
  • Optimum people & equipment usage, improved OEE
  • Fast trouble shooting, inventory optimization
  • End-to-end visibility & decision insights
 Productivity
Energy Efficiency
Warehousing
Inventory
Changeover
Waste

Assess Your Digital Maturity

infographic 2

What stage are you in your plant Digitization Journey ?

Siloed & Manual
Automated
Connected
Optimized
Autonomous
Technology Index
Description
Score
NA 1 2 3 4 5
Data capturing
Sensors & actuator data capturing carried out for critical assets in the plant.
Data connectivity
All critical assets are connected on SCADA, DCS or PLC control.
Data Storage And Retrieval
All data captured from critical assets are stored for future analysis & archival for recall management.
Data Processing
Data is processed & used for analysis. Example: Pre-processing, aggregation, tag security etc.
Data Integration
Data integration possible with business application, business work flow & data from other systems.
Modelling & Analysis
Data modeling & analysis carried out on data which is captured & stored from critical assets.
Visualization
Data visualization is present for ease of decision making & actionable insights.
Automation System
Use of automation systems for critical assets, including supervision, control, monitoring & data acquisition.
User Experience
User interface with minimal manual intervention to take necessary data based decision.
Security & Access Control
Data capturing, storing & access are controlled at data tag level, user level and storage level etc.
Cloud & IIoT Ready
Operations data is being stored in cloud, while cloud readiness & implementation for OT data being strategized & operationalized
Business Index
Description
Score
NA 1 2 3 4 5
Sourcing
Sourcing of raw material, vendor selection, commercial negotiation & other S2P systems enabled.
Planning
Supply chain planning system is used for Demand, Supply, Production, Distribution & Maintenance.
Production
Operations & Production work flow with production & process order is being monitored with material tracking.
Quality
Quality monitoring & control enabled across Raw Material, Packaging material, Work in Process & Finished goods level.
Maintenance & Utilities
Maintenance system is being utilized with spared inventory management, maintenance crew planning etc.
Safety & Sustainability
Safety & Sustainability system for Energy, Safety & Health monitoring is being used & monitored.
Operator engagement
Operators training & feedback for User experience design and operator utilization data capturing is enabled.
Critical Assets
Critical assets utilization, efficiency & downtime monitoring, defect & unplanned failure monitoring & control is enabled.
Warehousing
Warehouse system is present for material flow from & to the production & quality center, material picking for distribution.
After Sales Services / Distribution
Distribution management system is used & integrated with other business application across the functions.
Financial
Financial monitoring & control for operations & Cost of goods sold is being monitored, Production cost per unit etc.

Note: This quick assessment is to give you a flavor of some of the parameters only. The detailed exercise will be more comprehensive.

identify your digital maturity Score:

What stage are you in your plant Digitization Journey ?

Your Score
Industry Benchmark
4.00, 4.00
3.00, 3.00
1 2 3 4 5

Click to answer few more questions

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FILL THE FORM TO REGISTER YOUR INTEREST FOR DETAILED ASSESSMENT

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Identify maturity of your Data Connectivity

Siloed & Manual
Automated
Connected
Optimized
Autonomous
Description
Score
NA 1 2 3 4 5
Are all critical equipment connected via DCS/PLC/SCADA/IoT?
How is equipment operations & maintenance KPI captured?
How is Process analysis being carried on operations data captured?
Are critical equipment connected with IT system (ERP, Maintenance) for remote monitoring ?
Are DCS/PLC write enabled for optimization algorithm interaction?
How are DCS/PLC upgraded to latest support OS & system version ?
How are DCS/PLCs health monitored ?

What stage are you in your plant Digitization Journey?

Find out what is the digital maturity of your process

Your Score
Industry Benchmark
4.00, 4.00
3.00, 3.00
1 2 3 4 5

1.25OUT OF 5

Data Connectivity Score

Salient features of the score

Siloed operations

Manual & ad-hoc data collection and analysis

Reactive Quality, Cos & Productivity improvement programs

Carry out Detailed Assessment to begin your Digital Journey :

Scale Your Digital Maturity
Journey

Asset Reliability Center

Designed to improve plant health, ARC is a one-stop solution to overcome unplanned downtime and undetected quality issues. It can help you simplify engineering, monitoring, discovery, and prediction across various manufacturing operations. With real-time condition monitoring and reliability predictions, ARC ultimately minimizes unscheduled outages, increases utilization, and augments productivity without fail.

Benefits:
  • >25% reduction in reactive maintenance
  • 2% - 5% improvement in overall yield
Explore More
Asset Reliability Center

Energy And Sustainability Manager

Energy and Sustainability Manager’s comprehensive plant asset modeling puts compliance at the center stage. The solution helps you in forecasting energy need, track consumption & KPIs, and compare performances to deliver on your goals. Through an integrated, compliance-driven approach, Energy and Sustainability Manager will help you accomplish energy cost savings of up to 10-15%.

Benefits:
  • Boosted operational efficiency
  • Ensured real-time monitoring of production
Explore More
Energy And Sustainability Manager

How Can LTTS Help?

How Can Ltts Help
  • Prebuilt digital assessment framework to evaluate plants on their digital /Industry 4.0 maturity
  • Defined deliverables & industry benchmark on 11 dimension of digital maturity
  • Identification of opportunity area as DMIs (Digital Manufacturing Interventions)
  • Roadmap & support in leading to optimized and autonomous factory of the future
  • Program management support in vendor selection & technology implementations

What Makes Us Different

Strategic partnership to foster innovation and accelerate time to market

Strategic partnership to foster innovation and accelerate time to market

Expertise in traditional and digital engineering across multiple indus- tries with repository of use cases

Expertise in traditional and digital engineering across multiple indus- tries with repository of use cases

‘Design Thinking’ led engagement approach

‘Design Thinking’ led engagement approach

In-house artifacts, solution accelerators & frameworks

In-house artifacts, solution accelerators & frameworks

We Helped One Of Our Client To Transform Their Factories Into Smart Factories Leading To Paperless Operations, Energy Efficient Plant And Data Driven Decision System.

Read More

Contact Us to Benchmark Your Organization in the Digital Journey

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