CBTW Smart Industrial Solutions / Otofacto

Lean practices, known for their ability to reduce waste and improve efficiency, can demonstrate a high return on investment (#ROI) by significantly decreasing operational costs and providing long-term advantages. However, the traditional lean practices that have been the backbone of manufacturing processes for decades are now facing significant challenges! The COVID-19 pandemic has proven that these conventional methods are not as resilient or effective in the face of global disruptions. (SDC executive) Key Challenges of traditional practices: - Supply Chain Disruptions: Post-COVID-19 impacts and other global events have exposed vulnerabilities, requiring more resilient and adaptable supply chain strategies. - System Complexity: The integration of mechatronic systems and IoT increases operational complexity, making traditional methods less effective. - Regulatory Pressure: Stricter quality and compliance standards necessitate advanced systems to ensure adherence without compromising efficiency. - Energy Control: Efficient energy use is essential for cost control and sustainability, demanding sophisticated monitoring and optimization technologies. Symptoms of Ineffective Practices: - High Downtimes: Frequent equipment failures and maintenance issues lead to production halts and inefficiency. - Increased Operational Costs: Inefficiencies and waste drive up costs, reducing profitability. - Inventory Build-Up and Overproduction: Excess inventory ties up capital and resources, leading to higher storage costs and potential obsolescence. - Quality Issues and Defects: High defect rates undermine customer satisfaction and increase rework and scrap costs. - Inefficient Resource and Energy Use: Wastage of resources and energy increases operational expenses and impacts sustainability goals. However, technological evolution is dramatically reshaping the landscape of lean practices. Integrating #industry40 technologies with #leanmethodologies known as #Lean40 offers a revolutionary approach that enhances operational efficiency, resilience, and profitability. Features that make lean 4.0 impactful: - Real-Time Data and Analytics: Provides immediate insights for better decision-making, increasing agility and responsiveness. - Predictive Maintenance: Reduces downtime by anticipating equipment failures before they happen. - Enhanced Supply Chain Integration: Improves coordination and communication across all levels of the supply chain. - Smart Manufacturing: Utilizes #IoT and #AI to optimize processes and reduce waste in ways traditional lean methods can't achieve. - Scalability and Flexibility: Easily adapts to changing production demands and market conditions, ensuring sustained efficiency and competitiveness. Read our article where we dive deep into impact of Industry 4.0 on Lean and Six Sigma methodologies- https://lnkd.in/e7yeuEzD

Our client is a multinational biopharmaceutical firm that required assistance in setting up its new production unit in Belgium. We assisted our client in meeting the high regulatory standards for their new production site in line with #GMP practices authorization and #FDA regulatory compliance standards. Additionally, we enabled the client to standardize and automate the production site, perfectly aligning with the #ISA88regulations for #automation. Let's dive deeper into the details: Client Challenges: - Non-standardized Equipment: Equipment from various suppliers needed standardization. - Unreadable Equipment for Automation: Required modifications to Piping and Instrumentation Diagrams (P&IDs). - Non-uniform Automation Philosophy: Necessitated tailored Functional Description Specifications (#FDS). - Regulatory Compliance: Needed to meet FDA and GMP regulations, especially for cleaning processes. Our Approach: Standardization: -We built and refined P&IDs. -Developed larger modules after creating smaller modules with proper testing and validation. -Connected the Equipment Modules (EMs) to form a fully automated unit compliant with #ISA88 automation standards. Building the Automation Philosophy: -Using a modular approach, we created small, efficient modules and then connected those modules into a larger unit. -Enabled #digitalmaturity by integrating Siemens #PCS7 to achieve control and monitoring. Functional Description Specification (FDS) - Standardized FDS: -Evaluated processes through RFIs (Requests for Information). -Established a unified automation framework for the production unit and facilitated collaboration among various suppliers. Standardized Cleaning-In-Place (CIP). -Adjusted equipment for common cleaning standards. -Improved cleaning efficiency to meet FDA’s best cleaning practices. The Results: -Enabled automated production: The site is fully #automated, achieving compliance with #FDAregulations and the ISA 88 standards for automation. -Interconnection achieved using Siemens PCS7: Processes are connected to the MAIN USER SYSTEM, monitored, and controlled centrally. -Improved Control of Operations: Enhanced precision and reduced production variability. -Error Reduction: Minimized human errors, ensuring consistent quality. -Operational Efficiency: Streamlined processes, leading to cost savings and reduced human reliance. -Regulatory Compliance: Met all FDA and GMP standards, ensuring global certification. By the end of the project, the client attained digital maturity and gained a strong foothold in #Industry40 initiatives. In an industry where such initiatives are difficult and complex, the client gained a strong #competitiveedge in the long run while improving product quality and reducing costs in the short term. Read our Blog to discover more- https://lnkd.in/e83Pwn4z

Strategic Partnership to Advance Sustainability and Digital Transformation in Energy-Intensive Manufacturing Across the DACH Region! We are excited to announce our partnership with joyn-coop and sustainable AG, dedicated to driving digital transformation and sustainability in the manufacturing sector across the DACH region. This collaboration marks a pivotal moment in our mission to empower energy-intensive factories with innovative solutions that integrate sustainable practices within the rapidly evolving Industry 4.0 landscape. By combining our extensive expertise in sustainability, digitalization, and organizational transformation, we will deliver actionable solutions that facilitate the sustainable transformation of manufacturing operations. Discover more about this partnership by reading our press release 🟡 https://lnkd.in/eqh9AqUb #SustainableTransformation #DataDrivenSustainability #Industry40 #EnergyIntensiveManufacturing #DigitalTransformation

Transforming Maintenance Operations with #Predictivemaintenance Our client is a global leader in engineering and technology, including innovative #healthcarescience solutions. They offer a laboratory diagnostics system solution for their clients. The client’s objective was to reduce the malfunctions of the system by making sure the throughput is uninterrupted, to achieve this, they wished to incorporate predictive service and maintenance solutions. We were brought on board to assist them in this initiative! We leveraged the SAS Data Management Platform, one of our partners, to implement the solution. Our Role: - Sensor technology integration: Integrating essential sensors to achieve the principle connection to the client’s database and enable data processing. - Predictive maintenance framework design: Utilized and implemented SAS data management platform and SAS data integration server. - Efficient analysis: Based on analytic models, in addition, data analysis to determine failure probability. - Process Automation: Leveraging SAS visual analytics and real-time data analysis to automate sensor data transmission and alert generation. In addition, we developed an e-mail notification service. This feature gave automatic warning with detailed information to the engineers to act on. - KPI Visualization: Customized dashboards for key performance indicators using SAS Visual Analytics and enabled predictive insights and trend analysis for proactive maintenance decisions. Attained results: - Assessment of the entire solution: More than 50 system families and process being monitored proactively. - Reduced downtimes: Thanks to the proactive service enablement replacing the reactive service, leading to a decrease by 36% in downtimes. - Optimized deployment of service technicians: Technicians now know in advance which parts are needed in a particular location. - Our structure and framework for predictive maintenance ensured increased flexibility. - Enabled #continuousimprovement: The solution evolves with the expansion of the analytical models and the data basis. The modular structure and #intuitiveframework ensures that our client team can make modifications on their own. Read our blog to discover how we offered a scalable, felxible, and a highly effective predictive maintenance solution. https://lnkd.in/eFs_4TUH #PredictiveMaintenance #Industry4 #SASMaintenanceSolutions #DataAnalytics #OperationalEfficiency

CBTW Partners with Timeseer.AI to Revolutionize Industrial Data Quality in Europe We're thrilled to announce our strategic partnership with Timeseer.AI, a game-changer in the OT/IoT data software sector. This collaboration is set to redefine the landscape of industrial digital transformation by focusing on the crux of all data-driven solutions – impeccable data quality. "Poor data quality is not a fatality. Together with Timeseer.AI, we're bringing data quality back to the forefront of data infrastructure," says Guillaume Ovtcharenko At CBTW, we pride ourselves on integrating technology and operational expertise to drive continuous improvements in the manufacturing industry. By joining forces with Timeseer, we will enhance our ability to diagnose and resolve sensor data challenges, unlocking new levels of ROI for our clients. Check out how we can support your company: https://lnkd.in/eDPFQexZ #TimeseerAI #DataQuality #ManufacturingExcellence #TechPartnership

We enabled our client to establish a robust and flexible workflow management system using Apache Airflow. 𝐂𝐥𝐢𝐞𝐧𝐭 𝐂𝐡𝐚𝐥𝐥𝐞𝐧𝐠𝐞𝐬 - Maintaining Databases: Network issues prevented access to a large Snowflake data lake. - Orchestrating Microservices: Manual tasks in the MES system led to inefficiencies. - Troubleshooting: Significant time was spent fixing data pipelines. - High Labor Costs: Continuous need for multiple personnel. - Inefficient Practices: Lack of centralization, transparency, and proper documentation. 𝐎𝐮𝐫 𝐒𝐨𝐥𝐮𝐭𝐢𝐨𝐧 - Accessing Databases: Used Apache Airflow for efficient data lake access. - Achieving Operational Excellence: Addressed errors and improved technology and code quality. - Reducing Manual Labor: Automated tasks, allowing operators to focus on business objectives. - Improving Practices: Centralized data and enhanced governance using Airflow's UI. 𝐑𝐞𝐬𝐮𝐥𝐭𝐬 - Enhanced Connectivity: Integrated five departments, fostering a data-driven culture. - Improved Efficiency: Operators focused on business objectives, enhancing overall efficiency. - Competitive Advantage: Provided a decisive edge with Apache Airflow. - Cost Reduction: Reduced the need for additional hires. - Added Value: Enabled non-IT personnel to manage data pipelines, fostering innovation. Our collaboration empowered the client to overcome their challenges, leading to significant operational improvements and a culture of innovation and efficiency. Watch our webinar 🟡 https://lnkd.in/ds3rJXHD

Transform Your Manufacturing with Data-Driven CSRD/ESG Initiatives Are you prepared to advance your Corporate Sustainability Reporting Directive (CSRD) and Environmental, Social, and Governance (ESG) initiatives in the manufacturing sector? Discover pioneering strategies in our latest article, "How to Successfully Drive Your CSRD/ESG Initiative with a Data-Driven Approach." In this article, you’ll learn how to: - Implement Innovative Methods: Enhance the accuracy and effectiveness of your CSRD/ESG initiatives using cutting-edge technologies and data analytics. - Deploy Strategic Solutions: Overcome the unique challenges of transitioning to data-centric sustainability practices in manufacturing. - Gain Deep Insights: Utilize data to significantly improve your environmental impact and drive substantial changes within your operations. Are you ready to revolutionize your sustainability practices? Read the full article for practical insights 🟡 https://lnkd.in/eweWcViE #CSRD #ESGData #Industry40 #ManufacturingExcellence #DataDrivenSustainability

In today's newsletter, dive into our latest article "Retrofitting Legacy Machinery with IoT-Ready Control Units." As industries continue to evolve, integrating modern IoT technology into legacy systems is transforming manufacturing operations. This retrofit approach not only extends the lifespan of existing machinery but also brings the benefits of real-time data, predictive maintenance, and process optimization. However, successfully retrofitting legacy machinery involves more than just updating hardware. It requires strategic planning and careful implementation to ensure minimal disruption and maximum efficiency gains. Explore how IoT retrofitting can future-proof your operations, enhance productivity, and pave the way for a smarter, more connected factory environment. Read the full article and learn more about how to revolutionize your manufacturing processes through IoT integration. #IoT #OperationalExcellence #DigitalTransformation

Our client is one of the largest manufacturers in the world, widely known for its premium top-quality products. The client collaborated with us to set up a key #analyticsproject. Project Objectives: The goal of the project was to #optimize production by utilizing data, enabling the client to meet other underlying objectives such as: - Improvement of OEE - Reduction of scrap yields - Lowered costs Our #Industry40 Initiative: 1) Initiated the analytics project by performing data consolidation to set up the network infrastructure: We set up a gateway server, connecting different PLCs. 2) Centralized the data using Databricks: Achieved a 360° view of data coming from various sources. 3) Set up a Databricks environment to enable statistical analysis and machine learning. 4) Standardizing and Scaling: Provided highly flexible and scalable services to extend the initial PoC in a short time with minimal costs. Our IIoT reference architecture included highly flexible and scalable technologies. 5) Achieved continuous improvement in the long run by implementing #selfserviceanalytics: Enabled process engineers to derive practical insights. Obtained Results: -Reduction in cost thanks to insightful #dataanalysis (preventing destructive testing). -Improvement in Quality Analysis procedures. -Improved decision-making thanks to dashboarding that can analyze high-volume production. -Enabled preventive maintenance. Realized ROI in the Long Run: -Scalability: The client was able to replicate the solution for similar machines, multiplying the ROI. -Re-usability: The solution was built such that with minimal changes, it could be used in different machines, covering the initial cost. -Unlocked potential: The interaction effect with the use of three different dashboards enabled the client to discover and build product plans to garner the best results. Overall, the client claimed the project to be of great significance and described it as a “huge success.” Industry 4.0 initiatives can be truly game-changing! Watch the webinar and discover the full scope of the project, gain the know-how, technical developments, and the obtained results. Webinar -Attaining process optimization using Industry 4.0 analytics project  https://lnkd.in/eqPpQXdH

Calling all senior executives, decision-makers, and operations managers in manufacturing, industrial sectors, and beyond! Are you in the ideation phase or early stages of #digitalization? Our latest whitepaper is tailored just for you, offering insights to develop an Industry 4.0 mindset and enhance efficiency through technology. Stay ahead in a market where digitalization is not just a trend but a business imperative. Don't miss out—click the link below to revolutionize your digital journey! 🟡 https://lnkd.in/eUgWPxmT #DigitalTransformation #Industry40