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  • Connected Manufacturing solution for remote monitoring of efficiency

Client


The client is a leading manufacturer of transmission line towers with operations across substations, infrastructure and industrial electrification projects, offering integrated solutions for a broad spectrum of power transmission and distribution undertakings. The client had factories in three different cities and wanted to gain visibility of the operations to analyze productivity trends, handle breakdowns and perform condition monitoring of 50+ key machines remotely from their headquarters.

Client
Challenges

Challenges


Accurately determining OEE

Overall Equipment Effectiveness (OEE) is a product of machine availability, performance, and quality of output. Hence, OEE is an all-encompassing measure of how effectively assets are being used in producing quality output.

Energy Consumption

Data available from various sources was limited in its ability to provide insights about energy consumption. There was a need to develop insightful analysis on major areas of consumption and explore the possibility of energy conservation to the best possible extent.

Business Benefits

By working with the LTIMindtree team and utilizing the powerful analytical insights derived from the platform, the client realized the following benefits:

 

Shift productivity improved by 2.5 hours through insight-based interventions.

Instantaneous ‘Machine Idle/Under Breakdown’ intimation through message triggered from HMI

Insights-driven energy conservation practices resulted in higher power saving.

OEE-based benchmarking provided an accurate picture of machine utilization and resulted in outsourcing cost reduction by 15%

Post-breakdown response time reduction from 30 to 5 minutes by digitizing the process.

Streamlined root cause analysis by replacing manual paper-based record keeping with HMI-enabled recording of breakdown causes.

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