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| Case Study |
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Leading FMCG company gets single view of shop-floor data across global locations |
Leveraging Patni's expertise in MES, a leading FMCG significantly improved its capability to track and
monitor plant performance across distributed locations.
The Client
The client is a leading FMCG company with a portfolio of 250 brands and operates in over 130 countries across the world.
The Challenge
In an era of increased competitiveness, the ability of the client to succeed is determined by the visibility and availability of information across all its locations. However, with plant locations spread across 80 countries across the world with each plant having its own Manufacturing Execution System (MES), the client faced a huge challenge in having an integrated view of data generated at the shop floor. Additional challenges included:
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Lack of a consolidated view into shop-floor data hampered the decision-making process |
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Inability to maintain consistent level of quality across all
manufacturing locations for particular products |
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Inability to monitor or set service level parameters at the shop-floor across all locations. |
Hence, the client needed a solution which would aid its decision making
process by transforming its local visibility into a global visibility.
The Solution
A team from Patni collaborated with the client to determine the exact business needs of the
organization. After assessing the business needs, Patni developed a solution that gave the
client complete visibility into its plant floor operations. The visibility was enabled by
implementing an enterprise portal which gave a single view by unifying the different
interfaces of the MES located at different plant locations. This solution was instrumental in
providing operational and plant performance intelligence to the client. Additionally, the
client had the capability to compare plant performance through standard and dynamic
reports. Significant Business Intelligence and dynamic analytic capabilities were also built
on to the system. Being a global organization, the system developed was localized in 14
different languages.
Solution highlights include:
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Global reports module with real time data for line managers, regional and corporate
managers for faster and well informed decision making |
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Universal data model for training, maintenance & safety related information |
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Provision of a global security architecture for accessing different levels of data and
reports. |
The Technology
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Hardware: JRUN 3.1 Server |
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OS/Language: HP-UX, C,C++ |
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Database: Oracle 9i release 2, Oracle Warehouse Builder (OWB) |
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MES: In-house Custom
Developed Tool |
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The Benefits
The global visibility of data to all employees enabled plant
performance of the different sites to be benchmarked with global
standards. This visibility enabled the plant managers to review and
align the performance of the plants against global benchmarks.
Further, plant managers could compare plant production
performance against planned schedules, plant resource
availability against planned availability and resource productivity
against planned productivity.
Other significant benefits include:
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Tracking of deviations in availability and productivity |
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Faster, efficient and effective tracking of unresolved problems and tasks |
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Effective tracking of trainings and skills availability of resources |
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Effective enforcement and logging of safety norms compliance |
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Improved traceability of root causes of failure to meet global benchmarks |
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Recording of incident details from opening to closure |
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Significant reduction in communication gaps between the plants, regional and corporate offices due to "single" set of data and reports which is globally accessible due to webenablement |
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Elimination of duplicate work across businesses and sites. |
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