Author: ecubix@admin

The fourth industrial revolution is here, and industry 4.0 has greatly influenced different industries. Industry 4.0 utilizes different modern and advanced technologies to establish a robust connection between the digital as well as physical systems. Top cement company Ultra Tech uses this technology & in their first year of operations they saved USD 1 Million, after basing 1755 use case on this platform*.

Industry 4.0 solution has brought opportunities to power up the overall productivity while lowering the environmental impact.
 Cement producers utilise Industry 4.0 solutions and other digital tools, to bring out the efficiencies which are hidden to human eyes by capturing & leveraging the hidden data regarding critical asset performance.
Once these captured data are analysed for a period of time one can apply machine learning solutions to predict the desired output and predict the period of time will this asset will function.

This enables organisational movement from scheduled maintenance model to Predictive maintenance model. This increases the availability of these assets and at the same time cost of maintenance comes down.
One makes some very visible increases in the OEE one of the key cost factors for any organisation.
Industry 4.0- Enabler to greener production processes
The global cement industry, which is very energy-intensive and produces greenhouse gasses, is subject to strict rules as well as environmental constraints. On the other hand, energy consumption has become a primary issue for every cement manufacturer.
 The cement-making process is quite complex, and the electricity and fuel requirements depend on different factors, like the method used to produce cement, quality of the cement, storage of materials, firing lines configurations, raw materials chemical composition, and more.
All these things can complicate energy optimization. However, industry 4.0, which combines IoT, Pi solutions for the cement industry, automation solutions, and more, is opening many new opportunities. Energy optimisation is the area where the data science is used most frequently.

The one biggest compliance issue for a manufacturer is the need for them to become water positive and ensure cleaner operations. The penalties are not only prohibitive but can also result in operation closure which is unthinkable for any investor.
Continuous data monitoring allows real time actionability and complete compliance in this.
Other direct beneficial outcomes of the data integration through creation of data lake having time stamped data capture are:

• Accelerate Growth by Performance Optimization through in-depth process study.
• Applying Industry 4.0 solutions and gaining competitive advantage. Utilising them innovatively to unlock hidden benefits makes sure that one is the most efficient in the industry. As the collected data becomes historic many lessons tumble out to ensure better operational future. Hence longer the term, higher is the competitive advantages. Impact of Industry 4.0 solution on The Global Cement Industry
• Analytic-Driven Predictive Maintenance. With a predictive maintenance solution, cement producers can effectively resolve different maintenance issues well in advance. As a result, they can prevent downtime and unnecessary maintenance effort simply out of a schedule timetable. Besides, helping in boosting operational efficiency and lowering the overall maintenance costs significantly.
• Digital Twin for End-to-End Optimization. Industrial organizations require a new way of operating if they are to address the multiple challenges affecting global markets head on. Geopolitical volatility, Environmental, Social, and Governance (ESG) commitments and disrupted supply chains heighten the pressure for engineers to quickly adapt. Having instant access to a single hub of trusted data enables the right people to make the right decisions when they need to. This is enabled using digital twin technology. A virtual representation of an object or system that spans its lifecycle all the while getting updated using real-time data. One needs expertise in simulation, machine learning and reasoning to make this work. In cement industry the digital twin can enable the cement producers to effectively mirror their production process through a well-designed digital model, and then they can optimize it by using machine learning and artificial intelligence. The digital twins can simulate the cement production process in a dynamic as well as simplified way. As a result, you can create scenarios that can easily change with variables. The best part of the digital twin is that it can suggest optimal and efficient equipment configurations that can help you to increase your output target.

Aveva (technology partner of ecubix) has white paper which puts digital twin benefits as:
Digital twin solutions are transforming engineering projects:
o 3 minutes or less to find actionable asset information
o 2 months to deploy across the full business unit with a cloud solution
o 10% increased staff productivity
o 30% or more reduction in unplanned downtime

Source-https://engage.aveva.com/rs/986-YIS-805/images/Whitepaper_AVEVA_AIM_EmbracingDigitalTwinTech_22-07.pdf

Trusted engineering data is at the core of every successful digital twin. Engineering data provides the structure from which the twin can be created and allows 3D visualization. Using predictive quality models, cement producers can forecast cement quality with near to 100 percent accuracy in real-time.
Ecubix creates digital twins through linking the machines through innovatively using technologies like the internet of things, embedded data analytics, machine-learning algorithms, & Pi solution for the cement industry.

• An Optimization of Supply Chain and Logistic- With the IoT for the cement industry, you can create a Smart Cement Factory that can offer you real-time supply chain information by effectively tracking products, equipment, materials, and more while they are moving through your supply chain.

 So, what are you thinking now? If you want to improve the production capacity while keeping your production cost and carbon footprint low, then it’s time to employ Industry 4.0. Besides, there will be greater visibility of every aspect of your business.

In the FMCG sector, the use of a serialization system, as well as a track and trace system, helps in maintaining transparency with the customer and optimizes the processes. The use of these systems helps in improving customer services. In addition to food safety practices and quality assurance testing, traceability, and serialization of FMCG products are of utmost importance for large-scale and small-scale businesses in the sector.

The benefits FMCG companies draw from the Product Serialization system

The use of product serialization systems can improve the operational efficiency of the FMCG companies for a better supply of safe and clean food products. Serialization systems can support the improvement of logistics and transport inside the FMCG sector.

Recognition of a low-quality product

The use of an end-to-end track and trace system helps in monitoring the quality of the FMCG product throughout the supply chain. The quality of short shelf life FMCG products can fluctuate easily and needs monitoring. Traceability and serialization step in to make a constant monitoring of product quality possible.

Serialization allows each partner in the supply chain to track product at every step, from point of manufacture to the moment it’s in the consumers hands. In addition, when the product is returned, the serial number can be used on all shipping documents to provide information on status and the reason for the return. The information can be of great value in determining whether the product has any quality problems.

Product serialization also helps in the identification of the fault or issue with recalled products so that the same issue is not repeated in future batches.
Therefore, the traceability of products helps the manufacturing companies too

Smooth flow of recalled products

Non serialized products can block the supply chain because companies, employees, and customers lose sight of the products and their status in the chain. Without the use of a proper track and trace system, the productivity of the supply chain goes down. When the FMCG products are serialized, the customers can get more information about the products they choose from the supermarket shelves. The use of product serialization codes also helps smooth the backflow of products to the seller because the products are easily tracked, and the logistics process can be optimized accordingly.

Demand management

The use of a track and trace system by an FMCG company can help increase the scope of demand management. The tracking of products with the help of the codes can help improve supply to the right demand points. The increased traceability of the products helps speed up the supply speed so that the demand in grassroots level stores is easily met within a certain timeframe.

Half of the business in the FMCG sector depends on supplying to the demand at the right time. Now, demand might not arise from a single audience segment all the time. Depending on the demand for the products over a period, the company must supply products to the stores selling them.

Traceability of products and the use of end-to-end track and trace systems help in demand management across different submarkets and stores. The use of product serialization codes can help the organization know which products have gone to which area. The implementation of these solutions helps in improving demand management and other processes linked with the supply chain.

Better impact on sales management and wholesale chains

When it comes to wholesale chains and sales dealerships, the use of serialization codes can help the company not only track the activity of the product down the logistics chain but also improves the prospect of the sales by letting the company analyze how the products are performing in the ground-level market.

The company can track the sales performance of different products and know why the performance of certain products is getting affected negatively. The use of trace systems provides crucial information to the marketing and sales team. The information can be used to control the sales funnel and the products that go out to the stores.

For example, the company can focus on either improving the quality of low-performing products or increasing the supply of high-performing products so that the revenue and profits increase further. The information collected from the product serialization codes can be used to analyze product performance and alter sales and marketing strategies for the company. The commercial strategy can be tweaked for specific results on the marketing and sales front.

The use of track and trace systems and serialization codes can have benefits for the business management sector, as well as the quality improvement sector in the FMCG industry. The companies can collect crucial data, analyze and create strategies for future industry benchmarks so that customers are satisfied and there is strong brand recall. The information collected can also be used to create a new production system and flow for better product quality in the long run.

The Benefits of Product Serialization and Traceability in FMCG

In the FMCG sector, the use of a serialization system, as well as a track and trace system, helps in maintaining transparency with the customer and optimizes the processes. The use of these systems helps in improving customer services. In addition to food safety practices and quality assurance testing, traceability, and serialization of FMCG products are of utmost importance for large-scale and small-scale businesses in the sector.

The benefits FMCG companies draw from the Product Serialization system

The use of product serialization systems can improve the operational efficiency of the FMCG companies for a better supply of safe and clean food products. Serialization systems can support the improvement of logistics and transport inside the FMCG sector.

Recognition of a low-quality product

The use of an end-to-end track and trace system helps in monitoring the quality of the FMCG product throughout the supply chain. The quality of short shelf life FMCG products can fluctuate easily and needs monitoring. Traceability and serialization step in to make a constant monitoring of product quality possible.

Serialization allows each partner in the supply chain to track product at every step, from point of manufacture to the moment it’s in the consumers hands. In addition, when the product is returned, the serial number can be used on all shipping documents to provide information on status and the reason for the return. The information can be of great value in determining whether the product has any quality problems.

Product serialization also helps in the identification of the fault or issue with recalled products so that the same issue is not repeated in future batches. Therefore, the traceability of products helps the manufacturing companies too.

Smooth flow of recalled products

Non serialized products can block the supply chain because companies, employees, and customers lose sight of the products and their status in the chain. Without the use of a proper track and trace system, the productivity of the supply chain goes down. When the FMCG products are serialized, the customers can get more information about the products they choose from the supermarket shelves. The use of product serialization codes also helps smooth the backflow of products to the seller because the products are easily tracked, and the logistics process can be optimized accordingly.

Demand management

The use of a track and trace system by an FMCG company can help increase the scope of demand management. The tracking of products with the help of the codes can help improve supply to the right demand points. The increased traceability of the products helps speed up the supply speed so that the demand in grassroots level stores is easily met within a certain timeframe.

Half of the business in the FMCG sector depends on supplying to the demand at the right time. Now, demand might not arise from a single audience segment all the time. Depending on the demand for the products over a period, the company must supply products to the stores selling them.

Traceability of products and the use of end-to-end track and trace systems help in demand management across different submarkets and stores. The use of product serialization codes can help the organization know which products have gone to which area. The implementation of these solutions helps in improving demand management and other processes linked with the supply chain.

Better impact on sales management and wholesale chains

When it comes to wholesale chains and sales dealerships, the use of serialization codes can help the company not only track the activity of the product down the logistics chain but also improves the prospect of the sales by letting the company analyze how the products are performing in the ground-level market.
The company can track the sales performance of different products and know why the performance of certain products is getting affected negatively. The use of trace systems provides crucial information to the marketing and sales team. The information can be used to control the sales funnel and the products that go out to the stores.
For example, the company can focus on either improving the quality of low-performing products or increasing the supply of high-performing products so that the revenue and profits increase further. The information collected from the product serialization codes can be used to analyze product performance and alter sales and marketing strategies for the company. The commercial strategy can be tweaked for specific results on the marketing and sales front.
The use of track and trace systems and serialization codes can have benefits for the business management sector, as well as the quality improvement sector in the FMCG industry. The companies can collect crucial data, analyze and create strategies for future industry benchmarks so that customers are satisfied and there is strong brand recall. The information collected can also be used to create a new production system and flow for better product quality in the long run.

 

Traceability has emerged as one of the most integral highlights of the manufacturing process.

One of the conventional assumptions regarding a Track and Trace system revolved around the notion that it is applicable only for products subject to recalls. However, product traceability must be a mandatory aspect of the manufacturing process of every consumer goods provider.

Product traceability introduces many promising benefits such as cost reduction, resource efficiency, and improved productivity. With the help of efficient tracking and tracing solutions, enterprises can strengthen their control over the production process on a granular level. Are track and trace a necessity for consumer goods industries? How does traceability work for consumer goods? Let us find the answers in the following discussion.

Definition of Product Traceability

Before you dive into the working of track and trace solutions, it is important to know the basic definition of product traceability. Product traceability refers to the ability to track all aspects of a product’s manufacturing and distribution.

Organizations with a competent tracking and tracing system can access data regarding the production lifecycle, product destinations, and inspection notes.

Types of Product Traceability

The next crucial highlight you need before deploying a track and trace system is to be aware of the types of product traceability. You must note that traceability focuses on many other things related to the product beyond its location. Product traceability also accounts for many other factors such as batch numbers, product use by consumers, inspection notes, product destination.

The two most common types of product traceability include upstream tracing and downstream tracing. Both of them have their unique advantages, depending on the traceability use case. Here is a brief explanation of the two types of product traceability systems.

Upstream Traceability

Upstream traceability refers to the process of tracing goods opposite to the logistical chain. The upstream track and trace solutions are applicable in the case of recalls which go back from the customer to the retailer and then the supplier. One of the common examples of upstream tracing is clear in the food industry. The European Union has imposed regulations for traceability of food products to ensure better customer protection.

Downstream Traceability

Downstream tracing refers to the process of tracing along with the normal flow of the supply chain. Therefore, product traceability starts from the sourcing point to the manufacturing stages before going through retail, sales, and consumer use. Most consumer goods companies use downstream track and trace system in the backend of their operations.

Why is Product Traceability Important for Consumer Goods Companies?
The demand for comprehensive and powerful product traceability solutions has been growing at exponential rates in recent times. Enterprises are actively seeking IT solutions for standardized tracking and tracing of consumer goods. Why? Here are some of the notable benefits of product traceability for consumer goods companies.

No More Counterfeit Goods

Counterfeit products are one of the biggest challenges for the consumer goods industry right now. Counterfeit goods present high risks as brands can lose sales potential as well as the trust of customers. The fashion industry is one of the biggest examples of a consumer goods industry facing the brunt of counterfeit products.

Effective track and trace solutions can help in verifying the journey of products from the stage of sourcing to the hands of the end consumer. As a result, product traceability can prevent counterfeiting in various sectors such as cosmetics, electronics, luxury goods, and spirits.

Compliance with Regulations

The next significant aspect pointing toward the necessity of track and trace solutions reflects on regulatory precedents for consumer goods. The constantly changing regulations in consumer goods industry focus on providing better consumer protection.
For example, the food industry has been witnessing a slew of updated regulatory standards. Product traceability helps consumer goods companies ensure that their products comply with new regulatory standards at all stages.

Proof of Origin

Many consumers are interested in figuring out the location from where raw materials for making the product have been sourced. Consumers are worried about the ethical concerns in manufacturing different products.

For example, buyers want to know that farmers have not been exploited for the coffee they enjoy every morning. Product traceability can offer flexible access to historical data regarding the sourcing of raw materials, thereby enabling easy verification of the product’s origins.

Implementing Product Traceability in Consumer Goods Companies
You can implement an efficient track and trace system for consumer goods companies with a clear idea regarding the essential requirements for the same. Here are some of the most important traits you need for implementing product traceability in consumer goods companies.

Serialization of product lots
Marking and labeling identifiers
Lot tracking and validation
Container recognition, labeling, and validation
Process tracking and validation
Process feedback and enforce improvements

Are You Prepared for Adopting Product Traceability?
Product traceability is more than just a necessity for consumer goods companies to earn the trust of customers. Effective track and trace solutions tailored according to your enterprise business objectives and market requirements can deliver promising benefits. Whether you are tracing the product from manufacturing to consumers or back from consumers to the manufacturers, product traceability delivers many productive insights. Find the best IT solutions for making the most of product traceability benefits right now.

 

Once you are a part of any manufacturing industry, Industry 4.0 will be a general point of discussion.

This is an age of competition and an issue of being first amongst equals. Once your competitor starts drawing advantages from applying Industry 4.0 solutions, you need to get it as well. In long run It may be a question of one’s survival. Present manufacturing technologies are evolving to fully encompass both automation information and data exchange. They are integrating all existing systems through using cloud computing with cyber-physical systems, augmented reality, and the Industrial Internet of Things (IIoT). In short, one’s journey to future does not even begin without applying Industry 4.0 solutions.

Benefits of using Industry 4.0

A. Increase of productivity- As already explained the three components of productivity get instantly affected positively through application of Industry 4.0 solution. Machine availability the biggest challenge is first benefit by ensuring better maintenance schedule and pre-empting breakdowns. The clear visibility in RM supply chain and quality output gives a much larger control over this one most important factor.
B. Remaining competitive- Proper management of efficiency in production and optimization of supply chain can help an organization to fulfill the orders of the customers in different market segments. On top of this effective distribution strategies helps an organization to remain competitive in highly competitive manufacturing industries.
C. Increased Knowledge sharing & collaborative working- Industry 4.0 comprises cloud-based information to share technologies that help sharing relevant information within different departments so that good practices by one can be shared across the organization virtually seamlessly. Also, it ensures dismantling of departmental silos so common in large organizations. Team collaboration which results makes it easier for the organization to achieve the organizational targets.
D. Cost effectiveness- The ability provided by Industry 4.0 platform is performing repetitive tasks without any error. The chances of human errors also remain less in this process. On the other hand, it also becomes possible for the organizations to re-organize their workers as per task complexity rather than task repeatability. As a result, the labor cost of the company per unit of production reduces significantly.
E. Flexibility & agility- Scaling of production up and down or to include new products lines becomes much easier. One has to only provide crisp SOPs for the changed process. Hence Industry 4.0 opens opportunities for one-off manufacturing systems and high-mix manufacturing systems.
F. Better customer experience- Quality enhancement and near instant root cause analysis ensures reduction of human errors in manufacturing. The overall control on each aspect of production and finished goods handling helps enhance the customer satisfaction. to manage the availability of the products in different markets so that the customers do not face issues in availing those products.

Challenges of using Industry 4.0

A. Cyber Security Issues- The use of IoT-based technologies and cloud- based technologies can lead to cyber security issues. Cyber-attacks performed on the servers and databases of the companies might lead to issues like data losses and data manipulation. Ecubix provides a highly protected platform and if demanded we can provide a security which is the highest possible in the industry. Through this we can assure no possibility of data theft or any kind of manipulation.
B. Technical issues- Improper maintenance of these technologies or inefficient handling of the machines can lead to technical issues. Such technical issues can also create inconveniences in managing operations. Ecubix provides a complete AMC of the systems it provides. Hardware to software. We are end-to-end service provider. This makes us the best possible maintainer of our systems.
C. Increase of technology maintenance cost- Any form of technology once applied is liable to get redundant as well as rendered useless as organization grows. However, the platform provided by ecubix is scalable to a virtually infinite level. Our customers have been with us since the time we have implemented solutions there.
D. Challenges related to employee training- After implementing industry 4.0, it is very important for the manufacturing organizations to train their employees properly for using digital technologies and smart machines in the production activities. Without proper training, they cannot handle those technologies properly and, it would lead to technical issues. Ecubix provides a continuous training through premade schedules as per the experience an organization gains though the industry 4.0 usage.

The concept of Industry 4.0- was coined to describe the phenomenon for merging of real and virtual worlds based on Cyber Physical Production Systems (CPPS).

It was evolved way back in 1960-70 aimed at enhancement of productivity of manufacturing organizations. Today Industry 4.0 is the current trend of automation technologies used for creating a smart factory. The figure below shows few components of Industry 4.0. Through these technologies we integrate different departments of the manufacturing companies to streamline their manufacturing operations.

Applications of Industry 4.0 in the manufacturing sector as implemented by ecubix. Ecubix inducts Industry 4.0 solution platform which provides:

A. Real-time information regarding the whole manufacturing process. The visibility thus created throughout the value chain allows optimization in:

• Raw material used in production,
• Logistics in the supply of the materials through different stages
• Origin of the material and it’s quality parameters
• Different activities associated with the production like improving production rate. Or in total quality management. Directly impacting OEE of the organization.
  Thus, distribution of resources and goods can be controlled effectively to manage the production activities effectively.

B. Next is bringing the risks of surplus production and the wastage of resources for surplus production in front. Implementation of Industry 4.0 is very much important for managing an end-to-end digital supply chain.
C. Provide data to organization in a contextualized form. This enhances the usage of data it’s understanding leading to improvement in the productivity of the workers.
D. Next is validity of the data. Generally, when data is used to create predictive models or applying AI to them 80% of the data analyst team gets used up in data massaging. The platform provided by ecubix provides a pre-validated data which makes it ripe to be instantly fed to AI tools.
E. Once validated data is available, we need to analyze the data using various statistical formulae. The platform has pre-embedded formulae or algorithms in it. What more it allows additional analytical tools to be embedded in it. Thus, it enables the stake holders specializing in their area of expertise to play with the data and freely come out with numerous efficiencies creating use cases. Our platform is completely free from coding needs.
F. Last but the most important part of any data integrating platform is its ability to provide visualization of such a nature that it enables the users to get a constant stream of decision enabling visual form which provides a near instant root cause analysis and an ability to simplify the processes in a manner where the operating team is able to take corrective action before any issue creates a loss making preposition.

Adoption of Industry 4.0 and IoT-based automation technology in the manufacturing sector Though many of large manufacturing organizations have shown interest to implement Industry 4.0. But after the pandemic the need of this has become a key reason for their success. Estimate shows by 2024 the organizations opting for the solution is expected to grow by 70%.

However, SMEs face different types of challenges in the implementation of Industry 4.0. The common issues being lack of talent and technical skills and the lack of resources and funds for implementing those automation technologies. However, ecubix has such unique process of implementing the solution that instantly within a period of three to four months organizations are able to realize cost savings to the tune that returns of their investment happens very fast. Before implementation the pilot evolves the system in such a manner that it is the operator level who grab the learnings first.

Do we decide from Heart or decide purely on meritocracy?
Should there be rules guiding the decision-making process?

Answer to both these questions is affirmative. But maybe this mythological tale from the Mahabharat may force you to think otherwise.

Drupada and Dronacharya were childhood friends. Their friendship was so strong that one day they decided they would share their possessions once they grew up. Fortune favoured Drupada who had become the king of the land of Southern Panchala while Dronacharya was in abject poverty.
Now, it’s natural for Dronacharya to be jealous but he did not feel that way. He simply wanted some help from his friend. For the sake of his wife and son, Drona desired freedom from poverty. Remembering the childhood promise given by Drupada, he decided to approach him to ask for help.

However, King Drupada refused to even recognize their friendship and said, “Friendship was possible only between persons of equal stature in life. As a child, it was possible for us to be friends with because at that time we were equals. But now I have become a king.

 “I would satisfy you nevertheless if you ask for alms befitting a Brahmin, rather than demanding your right as a friend. He added.
Drona went away silently, but in his heart he vowed revenge. This rage made him the martial arts specialist who trained all the Kaurvas and Pandavas. Dronacharya exacted his revenge on the battle of Kurukshetra from the epic Mahabharata.

The question arises, was Drupada wrong?
 His conduct was wrong surely. He broke the promise made to friend but now he had a responsibility. He couldn’t have parted with half his kingdom to a friend and throw his subjects to his friend’s mercy. The subjects trusted him; how could he deceive them. As a king, he shouldn’t participate in granting personal favours. This would set a wrong example for his council of ministers and officers. So, he did the right thing by not breaking the rule.

However, on the other side we see Lord Krishna in Mahabharata who keeps bending rules. Was that wrong? Lord Krishna maintained fairness, aren’t rules and codes of conduct created to ensure fairness?

When rules do not generate fairness it’s time to bend them and ensure they meet the purpose. Understanding the purpose of code of conduct helps the leader bend it when the situation demands it. Thus, it seems that purpose is more important than rules and fairness is of paramount importance.

So at one place rules are to be used but in case the same come in way of fairness and humanity the decisions needed to be made differently.