Tata Consultancy Services Case Studies Bekaert's Journey to Manufacturing Digitalization with TCS

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	Bekaert's Journey to Manufacturing Digitalization with TCS Tata Consultancy Services

Bekaert's Journey to Manufacturing Digitalization with TCS

Tata Consultancy Services

Technology Category	Functional Applications - Manufacturing Execution Systems (MES) Platform as a Service (PaaS) - Application Development Platforms
Applicable Industries	Electrical Grids Equipment & Machinery
Applicable Functions	Maintenance Quality Assurance
Use Cases	Additive Manufacturing Inventory Management
Services	System Integration Testing & Certification
Challenge	Bekaert, a major player in the steel wire industry, was facing significant challenges in its manufacturing operations due to outdated data platforms. The company was unable to trace genealogy beyond a week's data and lacked diagnostic analysis of plant operations, which severely hampered decision-making. The absence of automation in benchmarking operations and extensive reporting on plant management further complicated the situation. To enhance efficiency and effectiveness in multiple focus areas, Bekaert needed a modern data platform capable of managing large volumes of data and generating actionable insights. The company aimed to drive quality, overall equipment effectiveness (OEE), and plant productivity based on these insights. Read More
About Customer	Bekaert is a global leader in the steel wire industry, with a reputation for quality and innovation. The company's operations are extensive and complex, involving multiple manufacturing plants around the world. Bekaert's commitment to continuous improvement and operational efficiency led them to seek a modern data platform that could handle large volumes of data and provide actionable insights. The company's goal was to enhance decision-making, improve overall equipment effectiveness (OEE), and increase plant productivity. Bekaert's partnership with TCS was a strategic move to leverage technology and data to achieve these objectives. Read More
Customer Name	N.V. Bekaert S.A Read More
Solution	TCS, using a design thinking-led approach, implemented an enterprise-wide data lake and data warehouse platform for Bekaert. The solution was built on the Microsoft Azure platform-as-a-service, Python, and Power BI, and was infused with accurate data from eight manufacturing execution system (MES) plants globally. A generic data ingestion solution was also created for easy configuration of a relational database management system (RDBMS). The entire solution was deployed 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. This comprehensive solution enabled Bekaert to drive near real-time insights on material flow, utilization, and quality parameters. Read More Log in to view content
Contents

Technology Category

Functional Applications - Manufacturing Execution Systems (MES)

Platform as a Service (PaaS) - Application Development Platforms

Applicable Industries

Electrical Grids

Equipment & Machinery

Applicable Functions

Maintenance

Quality Assurance

Use Cases

Additive Manufacturing

Inventory Management

Services

System Integration

Testing & Certification

Challenge

Bekaert, a major player in the steel wire industry, was facing significant challenges in its manufacturing operations due to outdated data platforms. The company was unable to trace genealogy beyond a week's data and lacked diagnostic analysis of plant operations, which severely hampered decision-making. The absence of automation in benchmarking operations and extensive reporting on plant management further complicated the situation. To enhance efficiency and effectiveness in multiple focus areas, Bekaert needed a modern data platform capable of managing large volumes of data and generating actionable insights. The company aimed to drive quality, overall equipment effectiveness (OEE), and plant productivity based on these insights.

About Customer

Bekaert is a global leader in the steel wire industry, with a reputation for quality and innovation. The company's operations are extensive and complex, involving multiple manufacturing plants around the world. Bekaert's commitment to continuous improvement and operational efficiency led them to seek a modern data platform that could handle large volumes of data and provide actionable insights. The company's goal was to enhance decision-making, improve overall equipment effectiveness (OEE), and increase plant productivity. Bekaert's partnership with TCS was a strategic move to leverage technology and data to achieve these objectives.

Customer Name

N.V. Bekaert S.A

Solution

TCS, using a design thinking-led approach, implemented an enterprise-wide data lake and data warehouse platform for Bekaert. The solution was built on the Microsoft Azure platform-as-a-service, Python, and Power BI, and was infused with accurate data from eight manufacturing execution system (MES) plants globally. A generic data ingestion solution was also created for easy configuration of a relational database management system (RDBMS). The entire solution was deployed 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. This comprehensive solution enabled Bekaert to drive near real-time insights on material flow, utilization, and quality parameters.

Impact #1	The implementation of the new data platform transformed Bekaert's manufacturing operations. The company was able to make data-driven decisions through a scalable data management system. The real-time insights provided by the solution allowed Bekaert to optimize man hour per ton and improve on-time delivery. The solution also helped Bekaert enhance overall equipment effectiveness (OEE), production capacity, and energy efficiency. Furthermore, the company was able to minimize fracture per ton and increase yield, implement diagnostic actions, and significantly reduce work-in-progress inventory. The collaboration with TCS has enabled Bekaert to become a data-driven organization, from the shop floor to the top floor.

Impact #1

The implementation of the new data platform transformed Bekaert's manufacturing operations. The company was able to make data-driven decisions through a scalable data management system. The real-time insights provided by the solution allowed Bekaert to optimize man hour per ton and improve on-time delivery. The solution also helped Bekaert enhance overall equipment effectiveness (OEE), production capacity, and energy efficiency. Furthermore, the company was able to minimize fracture per ton and increase yield, implement diagnostic actions, and significantly reduce work-in-progress inventory. The collaboration with TCS has enabled Bekaert to become a data-driven organization, from the shop floor to the top floor.

Benefit #1	Mitigated machine failure, enhancing uptime
Benefit #2	Increased equipment and production line productivity
Benefit #3	Reduced maintenance costs

Benefit #1

Mitigated machine failure, enhancing uptime

Benefit #2

Increased equipment and production line productivity

Benefit #3

Reduced maintenance costs

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Overview

Bekaert's Journey to Manufacturing Digitalization with TCS

Operational Impact

Quantitative Benefit