Case Studies

ADITYA BIRLA GROUP

World’s leading manufacturer of Electrical Ceramics
  • Quality improvement by over 10%
  • Improved uptime of over 18%
  • Improved performance

Aditya Birla Insulators is India’s largest and the world's fourth largest manufacturer of electrical insulators.
As part of its journey towards “Smart Manufacturing”, ABI implemented Manufacturing Intelligence System at their factory

Objectives

  • Reduction in Manual Checkpoints and Errors
  • Increased productivity and efficiency
  • Improved Machine Utilization
  • Real-Time monitoring and Analysis
  • Timely information of faults
  • Correlation of Process Parameters with Quality

Challenges

  • No existing Sensors or Controller for capturing process data
  • Manufacturing process requires setup to be changed frequently. Hence sensor selection and installation was a challenge.
  • No precedence or existing use case of similar machines
  • No disturbance to the existing processes was required

Benefits

  • Digital Logbooks
  • 360 Degree View of Operations
  • Data directly from sensors
  • True OEE
  • Online Real Time Information
  • In Depth TPM loss analysis
  • Increased Operator performance
  • Automated Scheduled / On Demand reports
  • Decreased downtime
  • Correlation of Process Parameters with Quality
  • End to End Batch Traceability