Duracell wants to fully rebuild the Belgian production site in Aarschot into a so-called Industry 4.0 factory by 2020. That should lead to an even more efficient production process. The company expects to save hundreds of thousands of euros a year this way. Devoteam accompanies Duracell within this digital transformation process.
The Snapshot
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Duracell aimed to transform its Belgian production site into an advanced Industry 4.0 factory to boost overall efficiency.
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The core challenge was preventing production losses by ensuring all employees had real-time information to resolve issues instantly.
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A central digital platform was implemented to integrate all production, planning and maintenance data into a single information hub.
A production line that does not produce the required quality or stands still means a loss of production. To avoid this as much as possible, Duracell wants each employee to have the accurate information at the right time. If something were to go wrong, they should know right away where to find the cause of the problem. The only way to achieve this is through a central platform where all information is gathered.
All information combined on one platform
Duracell asked Devoteam as a Digital Transformation partner, and Ometa as an innovation partner. First, they made a roadmap together. “The idea behind the roadmap is to build step by step a digital platform where all data from the production site comes together in real time with information including production planning, maintenance and storage of the batteries,” said Arnold De Ploey, Digital Workplace Consultant at Devoteam. “The role of Ometa is very important in achieving this goal. The company offers a unique integration platform that allows business applications such as ERP systems and production systems to be linked to a portal and Content Management Platforms such as Microsoft SharePoint. “That is how all information on production planning, production quantities, drop-off, maintenance, safety and quality control will automatically flow into SharePoint. This used to be manually processed at different places.”
Accurate information at the right moment
Once they achieve this, the operation of the production teams at Duracell can be further digitised. “Computers and tablets will become the starting and end point in the daily operation of workers. Tasks are assigned through the devices and highlighted in red, which means they have to be carried out first. When done, the workers mark them as completed and they disappear from the screen. This will be processed automatically on SharePoint through dashboards that visually display KPI’s and the status of tasks. This way we always have the latest information. ”
Predictive maintenance and quality management based on machine learning
The new digital platform centralises all production, planning, and maintenance data into one integrated system.
The solution digitises workshop operations, providing staff with real-time, task-based information via tablets and dashboards.
The automated information flow significantly improves production efficiency and provides the foundation for predictive maintenance.
After digitising and combining all business information on one platform, Duracell also wants to speed up the process in the field of predictive maintenance and quality management. This is very important in order to reduce production losses. “Sensors are getting cheaper, more versatile and easier to integrate into the production process. More and more measuring points will constantly monitor the production process. Based on the sensor signals and through machine learning, the transition will be made from reactive maintenance to preventive maintenance. In addition, it will ensure better management of the production quality.”