119 execution, tracking the transformation of products from raw materials to finished goods, while evaluating and analysing yield, quality and plant resource utilisation. To improve asset performance management, Schneider Electric installed AVEVA Insight, and co-developed AVEVA Discrete Lean Management, new software specifically targeted to streamline discrete manufacturing. Together, the solutions continually monitor assets in real time to identify, diagnose and prioritise impending equipment problems. The AVEVA software was deployed on the richness of Microsoft Azure. The two companies have a history of creating a powerful ecosystem that enables industries to achieve their business and sustainability goals. Joint customers can deploy faster, reduce energy consumption, cut emissions and share innovations, realising system-wide efficiencies. Early business benefits in Batam included a safer and more efficient factory, optimised asset and process efficiency, and more secure and reliable operations. Within a short time of the implementation, Maintenance 4.0 had helped the Batam Smart Factory reduce downtime by 44 per cent over 12 months. Digital performance management tools led to 12 per cent higher operational efficiency and five per cent greater employee engagement. Quality 4.0 for defect reduction led to a 40 per cent decrease in scrap costs for some critical machines, while an integrated supply chain increased suppliers’ service rates by 70 per cent. As a result of the entire programme, on-time delivery improved by 40 per cent. Most important for the team was how Industry 4.0 capabilities connected the shop floor to the top floor. Unlike in the past, performance can now be tracked in real time, enabling business leads to quickly make data-driven decisions in line with immediate market pressures. Across the value chain, improved resiliency strengthens trust and enhanced efficiency reduces the plant’s carbon footprint. The Batam facility now offers global manufacturers a template for best in-class digital manufacturing: it was recognised as a Fourth Industrial Revolution Lighthouse by the World Economic Forum. Schneider Electric has since extended knowledge gains from Batam across its worldwide network. Like Schneider Electric, early digital adopters in the manufacturing sector fared better during the pandemic. From smart factory initiatives to e-commerce transformation, digital initiatives can support resiliency, maintain momentum and enhance sustainability. With the right digital toolkit, manufacturers can build a sustainable and competitive future. Kim Custeau is senior vice president of asset performance management and manufacturing execution systems at AVEVA MANU FAC TUR I NG & R E SOUR C E S
RkJQdWJsaXNoZXIy NzQ1NTk=