The inability to trace genealogy beyond a week’s data and absence of diagnostic analysis of plant operations hampered decision-making for Bekaert.
Lack of automation in benchmarking operations and extensive reporting on plant management posed challenges for the customer. To increase efficiency and effectiveness in multiple focus areas, Bekaert wanted a modern data platform that manages large volumes of data and generates actionable insights. The need of the hour was to drive quality, overall equipment effectiveness (OEE), and plant productivity based on insights.
Using a design thinking-led approach, TCS implemented an enterprise-wide data lake and data warehouse platform for Bekaert.
To implement the solution, the team leveraged Microsoft Azure platform-as-a-service, Python, and Power BI, infused with accurate data from eight manufacturing execution system (MES) plants globally. The team also created a generic data ingestion solution or easy configuration of a relational database management system (RDBMS).
TCS deployed the entire solution in five different sprints, delivering around 60 user stories, which were consolidated in Power BI dashboards for end-user consumption. The deployment also involved implementing business objectives, including ideation and brainstorming, to identify key performance indicators (KPI) and collaboration between business and IT for feasibility analysis. All these measures helped the customer drive near real-time insights on material flow, utilization, and quality parameters.
TCS helped Bekaert make data-driven decisions through a scalable data management system.
This mitigated machine failure, enhanced uptime, and increased equipment and production line productivity, thereby reducing maintenance costs.
The real-time insights provided by the solution optimized man hour per ton and on-time delivery. This helped Bekaert:
Enhance OEE, production capacity, and energy efficiency
Minimize fracture per ton and increase yield
Implement diagnostic actions
Slash work-in-progress inventory
what made this happen