Shaping the connected smart factory with hybrid-SaaS
Schneider Electric’s Lexington Smart Factory is one of the world’s most forward-thinking plants. Recognized by the World Economic Forum as an Advanced Lighthouse for Sustainable Manufacturing, this 62-year-old brownfield site has become a model for Schneider Electric’s factories around the world, with a digital innovation strategy built on IIoT connectivity, edge and predictive analytics.
Every day, the Lexington plant produces more than 16,000 finished products. It’s a large and complex operation — and as it continued to expand, the team found that traditional paper-based reporting was holding them back. They came to us looking for a way to digitize and harness data, so they could unlock silos, drive process efficiency, and advance their sustainability ambitions worldwide.
We helped the team enhance overall plant efficiency and safety by pairing Schneider Electric’s EcoStruxure Solution with a hybrid SaaS environment including AVEVA™ Edge, AVEVA™ Discrete Lean Management, and AVEVA™ Insight on our industrial cloud platform, AVEVA™ Connect.
The first step was to capture data. With the power of AVEVA™ Edge, critical WIP information is pulled from Schneider Electric’s PLCs and streamed to the AVEVA™ Insight operations and asset management platform in the cloud.
From there, AVEVA™ Discrete Lean Management makes critical information available when and where it’s needed. Production floor staff are connected with machine performance data through mobile notifications, driving major improvements in data visualization, safety and decision-making. With AVEVA™ Insight, the team was also able to bring data previously stored in spreadsheets into a cloud-based dashboard, enabling plant-wide visualization via real-time process data that is easily accessible and shareable.
As well as delivering big improvements in efficiency and operational excellence, the new system has enabled the team to drive impressive gains in critical ESG criteria, cutting energy usage by 26%, water consumption by 20%, and CO² by 78%, in conjunction with renewable energy credits.
Today Lexington is a showcase for Schneider Electric’s digital transformation and sustainability vision, with its lean management solution deployed in over 90 Smart Factories worldwide. By combining IIoT connectivity with both edge and predictive analytics, the team is able to drive new levels of process efficiency while helping to advance their sustainability ambitions.