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"Digital Transformation"

Aligning shop floor to top floor seamlessly. That’s engineering.

As the demand for agile product development grows, so is the need for Industry 4.0. With 10,000+ employees at 38 locations, the customer - a global leader in overhauling wanted to address manufacturing efficiencies. Tata Technologies helped the customer build a robust quality management system and closed-loop feedback MES application for higher productivity.
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Challenge

As the demand for Agile development is growing, so is the demand for Industry 4.0 implementation. The customer’s ecosystem was unable to keep up their operational efficiencies and ensure a thorough visibility into the processes. Moreover, the customer was incurring high maintenance cost due to its 15+ year old legacy MES application. To address this pressing challenge, the customer chose Tata Technologies, a global leader in digital engineering services, to transform its operational data management framework in line with the requirements of the Industry 4.0 model.

Solution

With multiple touchpoints across the manufacturing processes, the customer needed the ability to quickly trace an entire development process, digitally identify causalities between the processes, and ensure that the datasets are consistent. Before Tata Technologies stepped in as the preferred partner, the customer had paper-based shop floor operations with no real-time visibility into global processes.

With digital shop-floor strategy assessment and extensive Industry 4.0 road mapping expertise, Tata Technologies helped the customer build a robust quality management system and closed loop feedback MES application with PLM for efficient process execution.

We did a deep dive MES tool comparison among 3 COTS products and gave a comprehensive MES recommendation, with the customer opting for ‘Apriso’ as the preferred MES tool. We successfully created a closed loop feedback of MES application with PLM (Delmia) & ERP (SAP) integration and accelerated MES roll-out across 7+ plants in North America, along with E2E support. The customer team was delighted with the Digital continuity framework and strategy for Industry 4.0 enablement. Our ready-to-implement MES roll-out template helped us to plan and execute the implementation in record time, while delighting the customer with a scalability plan through hybrid operation model.

Tata Technologies was uniquely positioned to deliver what the client needed with our end-to-end data management capabilities and extensive prior experience in helping various leading global OEMS power their transition to Industry 4.0. Not only was the customer able to improve operational efficiency while eliminating manual work, but also achieved 100% real-time visibility to as-built records as compared to current state, while saving approximately 30% roll-out time.

Highlights

7+ Plants
MES rolled-out
30%
roll-out time reduction

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