The Age of
Performance

To reach their goal, Henkel needed a better way to capture, understand and communicate energy consumption and emissions data from across Laundry and Home Care’s global supply chain. At the same time, they wanted to cut energy consumption across production sites, using ISO 50001 standards as guidance.

Early in the project, Henkel identified the need for a new environmental management system, able to integrate with legacy hardware and assimilate with future hardware communications standards.

We helped them create a new energy monitoring system based on AVEVA software. As of 2020, the system incorporates more than 4,000 physical and virtual sensors, capturing over one million data points a day across electricity, fossil fuels, compressed air, steam, water and sewage.

Today, the system is used by more than 2,000 employees to easily observe and analyze performance and identify possible improvements.

As well as delivering meaningful progress towards sustainability goals, the solution has saved Henkel €37m to date. That equates to full payback four times over — with 100% ROI delivered after less than four years.

Almarai manufactures a huge range of products across dairy, fresh juices, infant formula, bakery and more.

Products are manufactured at multiple sites across the region before arriving at a central distribution center and replenishment hub. Here, they’re checked and sent on to market, enabling Almarai to ensure quality and respond to fluctuating demand.

We helped Almarai introduce AVEVA software to provide real-time visibility into filling and packaging performance.

Now, the team can make more informed decisions, better support their supply chain strategy and produce more food, more efficiently for people across the region.

We worked with the team to develop a cloud-based system, purpose-built to drive lean work management practices and enable data-driven performance measurement in discrete manufacturing.

The result is a novel software application that enables complex analysis of Schneider Electric’s vast manufacturing operations.

With digital process management and real-time visibility into shop floor operations, the new cloud-based system has delivered an impressive 10% increase in worker productivity and 70% faster response time through automated escalation of issues.

After successful pilot programs, the team has since scaled deployment to more than 100 manufacturing sites in just three years. Today, five of the factories have been designated global sustainability lighthouses by the World Economic Forum, driving sustainability and innovation best practices for the entire sector.

Danone’s Specialist Nutrition team needed a way to standardize processes and reporting across their many global sites. The existing system relied on manual entry and processing, which undermined productivity, reduced throughput and made it difficult to quickly understand and assess data.

The proposed new system was designed to solve those issues, helping to preserve traceability, assess factory usage, measure true performance, and provide a strong digital foundation for the future.

We helped Danone develop a core MES model (DANMES), based on AVEVA software, with 20 standard functionalities, including pre-approved FDA compliant processes for quality functions.

The system has been successfully deployed at the manufacturer’s Indonesia site, and is now being rolled out across the Specialized Nutrition division’s 25 plant sites.