Digitalization Solutions / Industry 4.0

Increasing Manufacturing Performance with IoT Analytics

Digitalization is transforming the manufacturing landscape as businesses embrace Industry 4.0 and Smart Manufacturing. At MIPL, we empower companies to design, develop, and deploy enterprise IoT systems and connected product solutions that align with their business objectives.

Digital Assessment

We begin by evaluating your current processes, equipment, key performance indicators (KPIs), and technologies to identify areas for improvement. This provides a clear baseline for understanding the current state of your operations and pinpointing potential for optimization.

Opportunity Identification

Leveraging industry best practices, we work closely with your team to identify opportunities for enhancing efficiency and productivity. Our focus is on developing scalable and efficient digital solutions tailored to your specific needs, while ensuring that system architectures integrate seamlessly with your existing infrastructure. This approach ensures that your current assets and technologies are fully utilized.

Conceptual Design

With the insights gained from the digital assessment and opportunity identification, we move forward with defining scalable and efficient digital solutions. Our conceptual design is centered around developing robust architectures that are not only adaptable to your needs but also poised for future growth, ensuring your operations are well-positioned to evolve with emerging trends.

Program Roadmap Development

A clear, actionable roadmap is essential for a successful digital transformation. We create a prioritized plan outlining estimated costs, business case inputs, and detailed steps that guide your journey. This roadmap takes into account the best opportunities for safety enhancement and optimizing Capacity Utilization, Performance Losses, Downtime analysis, First Time Pass (Quality), Material and Energy Consumption, and Overall Equipment Effectiveness (OEE).

Solution Validation & Implementation

Before full-scale deployment, we ensure that our solutions meet your performance expectations. By validating the system's capabilities and system architecture, we ensure that your digital solutions are aligned with your operational goals. This validation also ensures smooth integration with existing systems, helping you avoid disruptions during the transition.

Service Engineer Development & Deployment

Once validated, we equip your teams with the expertise needed to implement and maintain the digital solutions effectively. By training service engineers and operational staff, we ensure that they have the tools and knowledge to deploy the solutions seamlessly, while empowering them to troubleshoot and manage these systems for long-term success.

Lifecycle Management

After implementation, we continue to provide ongoing support and optimization to ensure that the solutions perform at their peak over time. This includes continuous monitoring, addressing emerging challenges, and refining the systems to keep them aligned with changing business goals. Our focus on lifecycle management ensures long-term success and helps in driving cost reduction initiatives, improving operational efficiency, and maximizing your return on investment.

What Sets Us Apart:

Our Business Value Assessment approach stands as a key differentiator. MIPL’s business analysts and software design experts collaborate closely with client teams to evaluate existing processes and systems. Together, we identify the costs and business benefits of implementing cyber-physical systems to unlock specific opportunities. With extensive experience across diverse IoT technology stacks and advanced edge analytics capabilities, we deliver innovative, results-driven solutions.

Applications

eLogbook - Batch Management Records

Digitalized shifts change reports, work permits, activity logs, and notifications.

Advanced Analytics

OEM’s AI-driven process optimization, predictive maintenance, and performance management improvements.

Safety Enhancements

By CMMS, tagging, automated LOTO procedures, and analytics to predict critical equipment failures and process abnormalities.

Start-up Sequence & Safety

Digitally capture startup sequences, authorized personnel entry, and minimize downtime for safer operations.

Capacity Utilization & Process
Optimization

Golden batch analysis, AI for optimizing raw material ratios, and automated production scheduling.

Quality Enhancement

AI-based quality prediction (e.g., moisture content), lab integration for batch records, and corrective actions.

Material Handling & Optimization

Chemical geology, material balancing, and optimization using DCS or analytics to reduce energy costs and solvent losses.

Utility Optimization

Improved control and analytics to reduce energy costs (5%-12%) and optimize plant-wide utility consumption.

Effluent Control

Process controls for reduced effluent, improved yields, and better separation phases.

Energy Monitoring Solutions

Real-time energy consumption monitoring and analysis to identify inefficiencies, optimize energy use, and reduce operational costs. Integration of energy data with predictive analytics for proactive energy management and cost reduction.