Smart Varroc, Auto Component Manufacturer leaps into Industry 4.0 using Datonis®

Real time OEE Downtime Analysis Conditional Based Monitoring

Varroc, a leading global Auto Component manufacturer was looking for a comprehensive solution to leverage Industry 4.0 initiatives for Enterprise wide automation across all its plants. This case study discusses how Varroc with help of Altizon’s Datonis®, the Industrial IoT Platform, began its IoT journey and transformed its factories into Smart factories. It elaborates on how Varroc connected all its disparate machines seamlessly, created a single data tunnel to analyze the parameters in real time, and achieved 20% improvement in OEE.

• 20% increase in Overall Equipment • Realize ROI right after the pilot in less than Effectiveness 12 months • 20% increase in Manpower Efficiency • Maintain sustainable competitive advantage • 5% decrease in Product Defects • • • • USECASES CUSTOMER HIGHLIGHTS HIGHLIGHTS temperature Monitoring for Spindle Conditionbased Energy conservation Analysis MachineDowntime Establish Realtime OEE • • • several the leverage As THE CHALLENGE • • • • • Varroc’s BUSINESS REQUIREMENTS 4 embracing countries, With car Automotive suppliers supplier A CUSTOMER PROFILE Automobile SECTOR . 0 $ Create Enable Implement Conduct Establish substitution both markets Lastly, vast, Secondly, underutilized diverse protocols machines, Firstly, . a and 1 energy . 35 3 part challenges the motorcycle that bn and IoT world IoT in a Varroc Condition of Varroc cutting – across new set Downtime | enterprise, . Single Component footprints the Real strategy Automotive the wherein the As their for Energy - . class systems, ‘dark’ platform of and such, maximizing market . amount Time faced edge Founded Industry Source at has companies assets 3 Based legacy manufacturing was Monitoring the the data and Analysis continents, primarily OEE Varroc technologies manufacturing the multiple Component leader handling outset of real and aimed . of maximizing Monitoring 4 on equipment data, in (Overall typical . Truth operational 0 bottleneck worldwide 1990 sensors, is : among initiative, to at they at data assembly it, a : driving machine, Centralize a Varroc , facilities, challenge needed leading Manufacturer Equipment they needed like single for types without capacity and two . is efficiencies, the all IoT spindle following are - in wheeler is suppliers to cell global and lines 11 integrating customer to communicating platform a data the of be any truly partner make Effectiveness) utilization and temperatures their innovating scalable emerging repository further with business passenger automotive plant a productivity, to a applications and primarily who push global leading IoT a . CAPEX levels and But diverse in global in requirements make could centers in on tandem flexible ‘Brownfield’ car component there Enterprise, to passenger wished for reducing different were Industry connect force lighting use set asset in . were with 10 so of of to in : • • • • RESULTS HIGHLIGHTS months Realize ROI in product defects 5% ManpowerEfficiency 20% 20% decrease in

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HIGHLIGHTSDamodaran Technology & Altizon ” • • • • • • Quick SAP Energy Condition Monitoring Centralized to that Further requirements triggered identify Systematic 2. 1. plant assembly Providing levels Reasoning Effectiveness), OEE identify monitoring any Machine Monitoring metrics centralized Testing (like By solution this the initiative Bolstering insights Integration requirements machine, Energy Integration a connecting pilot increase indirect number Insights of Operational improvement Due ROI time considerable the success, Monitoring level Honing, the in (Overall bottlenecks the Monitoring Condition on across tool . project near meters of helped to machines & data And Machine machine lines as and not cell and with Inventory Production Maximizing could Idle tools platform the processes into of manpower Machine consumption in . for real with only per analysis Press, people drill they and Manpower . Energy 30 Production Equipment their Efficiency allowed and reduction time real The them current were working time it which now more monitoring a (including down Data in the pushing escalation etc connected are needs time existing Planning payback – pockets real plant . achieve employed Utilization, Injection Consumption . (alerts bottom be a connected reports Line Visibility reduction ) locations operations decision into has now OEE capital single and time Efficiency and at in monitored Variance, Effectiveness), to the level Efficiency ERP labor specific shifts, and period that shop and . inventory led 10 & and planning their line, plan shop immediately are data molding, reduction source . in . % notifications) and makers systems Performance, has Lean can a and to and downtime, data for . It now but reduction predefined OEE in floor, tool was floor, machines from based Accurate at an served energy) real now helped future Machine also consumption Manufacturing was of entry to available cell, health less . has almost Hobbing to Varroc heterogeneous like time Altizon truth never horizontally OPE the reduced see on monitor scale in have than machine of seen SAP whenever could to to . objectives Idle dashboard direct top these for Quality, business could Efficiency inefficiencies 20 the be (Overall anywhere , 12 manage also up provided led time line, % a Pick all by missed be progress . monitoring months running programs tune considerable metrics and/or use to reduced increase Operational 2 deploy Varroc needed created pockets % right advanced machines Condition & ensured Process different process of leading . energy and across . Place, for Alerts . costs plant With after 20 at . The and IoT . the the % at to at in & a a ABOUT ALTIZON

Altizon is the creator of the Datonis® Enterprise IT-OT Grid by enabling an Intelligent Connected Ecosystem for the Industrial Internet of Things. We enable digital transformation in enterprises by accelerating Smart Manufacturing initiatives, modernizing Asset Performance Management and pioneering new Business Models for service delivery. The Datonis® IIoT platform, accelerates IT/OT integrations by helping quickly connect diverse industrial assets and launching new applications over a hybrid infrastructure with edge computing, advanced in- stream, an application development framework and Deep Learning capabilities. A set of ready-to-go Apps, Enterprise Integrations and Data Services for Operational Intelligence, further accelerate enterprise outcomes. With a global footprint of over 100 enterprise users, Altizon is a leading Industrial IOT platform provider as recognized by Gartner and several other analyst firms like Forrester and BCG. An award-winning company, Altizon, is also an alum of the Microsoft Accelerator. For more info: www.altizon.com

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