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Factory of Future at
Greenfield Automotive Plant
Digitally transformed end to end operations of a leading Indian automobile manufacturer

About the Customer

One of the leading Indian multinational car manufacturing corporations. Pioneer in tractor manufacturing and the largest vehicle manufacturer. A conglomerate split across 9 segments across the globe.

Challenge

End to end implementation of IT, digital manufacturing and automation for Greenfield project at the customer’s end.

  • Integration of shops at Greenfield site, ensuring seamless information flow
  • Reduction of capex by implementation of digital manufacturing tool
  • Automation of floor operations using robotics
  • Continuous monitoring and control

Strategy

We ensured timely delivery and execution of all the business requirements with scalable and adaptable solutions.

  • Digital Manufacturing & Simulation
  • Robotics & CNC Machines
  • Implemented $40 million complex MES & IT system for 20 shops across 230 acres Greenfield site, complete with fiber, wireless & MPLS cloud to support 20 large shops spread across 700 acres
  • Seamless implementation of live operations by BOM Management, Factory 3-D Layouts and Logistics Planning
  • Integrated SCM, JIT & JIS for assembly
  • Production monitoring and error proofing
  • Leveraged modern networks architecture and enabled Internet of Things for more flexible and efficient production
  • Implemented plant floor automation of Robots, CNC, and PLC’s for real-time controls
  • Provided visual diagnostics on site & remotely in addition to monitoring performance & maintenance
  • Creation of simulation files & offline program generation

Impact

  • Reduction in lead time to procure plant equipment, leading to accelerated production ramp up
  • Implemented digital tools to assist the plant in reducing capex by 15% with plant simulation and 3-D
  • High availability, determinism & redundancy with less than 100ms response determinism guaranteed
  • Increased re-use of manufacturing tools for simulation studies
  • Maximized production resource utilization and throughput

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