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Industry End Users

Sustaining Operations

Improving productivity, reducing downtime and improving operational efficiency with optimum investments.

What is Sustaining Operations (SO) Portfolio?

The solutions that utilizes the investments made on the existing plant assets to their maximum potential to improve performance, thereby helping the customers sustain and grow in the competitive business environment.

One of the common phenomenon of manufacturing business towards sustenance is to have continual improvements on their machinery performance, process performance and efficiency of operations. The internal business objectives of every manufacturer is to extract the best utilisation of the existing investments made on their plant and machinery and to extract enhanced productivity through incremental investments by topping up efficiency of those assets to produce more. BASE provides SO solutions to achieve the following objectives of:

  1. Increasing capacity by improving the Machine/Process Performance through deploying control automation systems.
  2. Reducing the set-up time changeover and improving operational flexibility by deploying operator friendly HMI (Human Machine Interface).
  3. Improving asset life cycle with reduction in maintenance cost and downtimes, through conversions, upgradations and migrations of legacy systems that justifies the ROI.

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Why is this required? How can I achieve these objectives?

One of the common challenges faced by the manufacturers is to keep in phase with the fast changing technology. Due to these changes in hardware and software, the deployed control platforms and software elements become obsolete, or sometimes lead to compatibility issues. Those technologies need to be upgraded to get support during maintenance which in turn reduces the cost of downtime and inventory. It is also easier to maintain similar kind of technology platform throughout the plant assets. This is becoming a standard practice of best-in-class manufacturers, which enables them to keep a standard set of spare parts as minimum inventory and resources with specific competencies to maintain those machines, thereby always keeping the plant up-time high.

  1. What is upgradation? – The control hardware and software of the running plant/machine would have hanged due to software technology upgrades such as the Operating System upgrading from Windows 95 to Windows XP. Due to this the firmware of the hardware needs to be suitably changed along with the software while retaining the functional performance of the machine.
  2. What is Migration? Machines/processes may have their control automation through specific brands of hardware that may have been declared as obsolete. There may also be machines/processes which are running with simple contactor logic to achieve their functional objectives. These types of systems can be easily migrated by retaining most of their I/O systems and replacing only their intelligent part (CPU and operator stations) with suitable compatible hardware with appropriate program conversions to make the machines/processes work on the latest technology with superior features.
  3. What is Conversion? To standardise the entire plant and to improve ease of maintenance, existing control systems of a specific “brand” needs to be converted to a much familiar brand (or platform).

What does BASE have which will help in achieving those objectives? Also, why BASE?

  1. Electrical, Control and Drive systems and special panels engineered to comply to specific global standards (CE, UL, Ex-proof Classified Panels) – We have a skilled team of experienced electrical/control designers, backed up by superior project management, who deliver manufacturing control systems within short timelines to execute projects within the stipulated shutdown duration.
  1. Integrated control system including PLC/DCS, with special interfaces, HMI, motion controls and SCADA for a specific process/machine application – We have an experienced team of trained and certified control engineers who understand any specific architectured solutions as per the sequence of logics defined by the customer, execute projects and exceed expectations.
  1. Upgrading, converting and migrating the control automation of an existing process/machine to improve productivity and ease of maintenance by solving technology/product obsolesce challenges – We have trained and certified control engineers working with multiple technology platforms and brands, performing upgradations, migrations and conversions in a short time span. We improve the operational flexibility while also achieving maximum utilisation of the new technology with minimum investments.
  1. Achieving new concept of a process/machine to meet specific functional objectives through Control Automation Solutions from designing to commissioning – All manufacturing companies drive continual improvements and address specific GAP’s identified in their process through innovative ideas. Many such creative ideas emerge as outcome of their six sigma and lean initiatives. This results in the need to conceptualise those creative ideas into real working solutions through control automation. BASE is a long time player in the industrial automation market space with varied domain and industry specific application expertise and can share the best practices adopted by the industry and convert those creative ideas to functional deliverables.
  1. Improved operational flexibility of the process/machine through creative visual guiding systems through HMI/SCADA solutions – Two common challenge faced by the industries are maintaining the skill level of the operators and managing resources to perform “more with less” with ”being right in first time”. This is achieved through deploying HMI/SCADA based visual guiding systems with flexible navigation, operator friendly interface, quick alerts, diagnostics and easy set-up. BASE has personnel trained on multiple HMI/SCADA platforms who can help in deploying the most compatible solutions with creative visuals to achieve flexible operative systems.

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High Performance Plant and Machinery on Turnkey

Specific technology solutions such as Intelligent Material Handling System that meets industry specific concepts and best practices.

What is High Performance Machinery on Turnkey (HPM) Portfolio?

HPM is application specific machinery for material handling systems that comprises of transfer to storage, feeding to measure and sequential control of processes to produce the output.

The system solutions are offered (custom designed) to suit the planned capacity and available infrastructure as per the customer’s needs through automated electro-mechanical systems.

Application specific HPM’s

1) High performance upstream equipment for Rubber Compounding:

Rubber mixing is a specialised process that involves various critical parameters to be kept under control. These parameters can influence quality and productivity while meeting the regulatory validations. The major automobile manufacturers are under pressure to meet specific regulatory compliances such as Motor Vehicle Safety Standards (MVSS), Transportation Recall Enhancement Accountability and Documentation Act (TREAD Act) etc. They then thrust this expectation throughout their supply chain from Tier-1 to Tier-2 Auto-component suppliers. The rubber parts producers that supply to Automotive, Auto-component and Tyre manufacturers need an integrated system to meet the expected quality levels demanded by their customers. Similarly, other industries producing consumer goods made of rubber (toys, condoms, footwear etc) also need a robust system to meet specific regulatory compliances while addressing the common challenges and meeting the productivity targets.

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The solution covers operational features and benefits of:

  1. RM receipts and qualifying – GRN tracking and quality checks.
  2. Storing – Visual guiding storage and operator friendly FIFO/LIFO based WIP issues.
  3. Inventory – Reconciliation of inventory.
  4. WIP transfer – WIP issue tracking with PO/WO.
  5. Reorder level – Proactive alert during batch plan to avoid stoppage due to material starvation.
  6. Visual guiding – Operator friendly guiding system to avoid any mix-up and contaminations using built in Poka-Yoke.
  7. Small ingredients semi-auto system – Sequential guiding measuring system with built in Poka-Yoke.
  8. Auto charging/sequencing system – Faster processing time.
  9. Maintenance – User friendly diagnostics and alerts for quick resolutions to increase up-time.
  10. Business Intelligence – Contextualise reports on production, quality, traceability, asset efficiency, and regulatory compliances.
  11. Enterprise connectivity – Linking production order, WIP status, and inventory of RM and FG with ERP for making business decisions.
  12. Need-based downstream equipment interface – Scalable from RM to FG stages of the process bringing in complete visibility.

What are the functional features and benefits of the system?

  1. The system is engineered to handle solids, liquids, and unit materials with suitable technology.
  2. Easy flowability ensured by selection and deployment of appropriate mechanised systems.
  3. Designed to meet the batch time and productivity within the capacity.
  4. Has the required protections to have clean environment of the plant.
  5. Built-in operator safety mechanisms.
  6. Meeting global standards of system compliance.

Why BASE?

  1. We have a consultative approach to understanding the customer’s needs through close interaction with subject experts.
  2. We have technical expertise in controls, software and mechanisation streams to provide a tightly integrated solution under the same umbrella with single point responsibility.
  3. We possess the infrastructure and resources to manage projects on turnkey through certified Project Management Professionals.

The upstream solutions on turnkey are scalable and modular with required customisations. The solutions are specific to industry verticals such as Automotive, Auto-components, Tyre, Consumer goods, Processed foods, and Pharmaceuticals. Our solutions can handle different raw materials for feeding, weighing and batching for rubber compounding and non-rubber applications.

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2) High performance upstream equipment for Non-Rubber Applications:

For the manufacturers of Fast Moving Consumer Products (FMCG), food products (Extractions, Processed food, Snacks, Spices etc.) and pharmaceutical products (formulations, API etc.) that have material handling processes in different stages from RM to FG. All these manufacturing companies need to meet regulatory standards such as FDA, HACCP and other region specific standards. They need to maintain process critical data for validations through deployment of supporting system built in their plant and machinery.

Though the process involves simple independent mechanised skid equipment for material handling, weighing and dispensing, batch mixing, blending and packing stages, it is imperative to have interfaces to the process utilities, CIP and SIP HVAC systems to meet global best practices of ISA88, FDA and regulatory standards with efficient productivity.

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The solution covers operational features and benefits of:

  1. RM receipts and qualifying – GRN tracking and quality checks.
  2. Storing – Visual guiding storage and operator friendly FIFO/LIFO based WIP issues.
  3. Inventory – Reconciliation of inventory.
  4. WIP transfer – WIP issue tracking with PO/WO.
  5. Reorder level – Proactive alert during batch plan to avoid stoppage due to material starvation.
  6. Visual guiding – Operator friendly guiding system to avoid any mix-up and contaminations using built in Poka-Yoke.
  7. Small ingredients semi-auto system – Sequential guiding measuring system with built in Poka-Yoke.
  8. Auto charging/sequencing system – Faster processing time.
  9. Online visual control and recording of integrated utility system – Regulatory Compliance.
  10. Maintenance – User friendly diagnostics and alerts for quick resolutions to increase up-time.
  11. Business Intelligence – Contextualise reports on production, quality, traceability, asset efficiency, and regulatory compliances.
  12. Enterprise connectivity – Linking production order, WIP status, and inventory of RM and FG with ERP for making business decisions.
  13. Need-based downstream equipment interface – Scalable from RM to FG stages of the process bringing in complete visibility.

What are the Functional Features and benefits of the system?

  1. The system is engineered to handle solids, liquids, and unit materials with suitable technology.
  2. Easy flowability ensured by selection and deployment of appropriate mechanised systems.
  3. Designed to meet the batch time and productivity within the capacity.
  4. Has the required protections to have clean environment of the plant.
  5. Built-in operator safety mechanisms.
  6. Meeting global standards of system compliance.
  7. Flexible control automation and software to any existing mechanised system through appropriate additions.

Why BASE?

  1. We have a consultative approach to understanding the customer’s needs through close interaction with subject experts.
  2. We have technical expertise in controls, software and mechanisation streams to provide a tightly integrated solution under the same umbrella with single point responsibility.
  3. We possess the infrastructure and resources to manage projects on turnkey through certified Project Management Professionals.

The upstream solutions on turnkey are scalable and modular with required customisations. The solutions are specific to industry verticals such as Automotive, Auto-components, Tyre, Consumer goods, Processed foods, and Pharmaceuticals. Our solutions can handle different raw materials for feeding, weighing and batching for rubber compounding and non-rubber applications.

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3) High performance plate coating and metal treatment equipment for discrete parts:

For the manufacturers who handle discrete metal parts that are to be treated or coated (anodising, zinc coating, nickel coating, phosphating etc.) through specific processes. A high productivity system is required by Auto-components industry.

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The solution comprises of:

  1. Single or dual transporter system with anti-collision logic and flexibility. Can be used with a single transporter if the other one is down.
  2. Tanks of specific capacity, based on the process requirement, with associated process/utility field elements connected. They are engineered with appropriate construction material that is modular and scalable.
  3. Customised designed fixtures and jigs to handle parts while meeting the production capacity within the process capacity.
  4. Intelligent control for sequential process with safety and permissive interlocks. Poka-Yoke is built in with sequential guiding for process adherence.
  5. Human Machine Interface (HMI) with software capabilities that has a quick changeover and setup time through powerful SKU based Recipe Management System (RMS) for process parameters. It improves productivity for mixed variants.
  6. Built in visual systems with diagnostics and alerts for easy maintenance and troubleshooting which reduces downtime.
  7. Scalable options that interfaces with ERP on traceability, productivity data and reporting.
  8. Control intelligence and software framework that is adaptable on any existing mechanised system by adding appropriate elements. It includes retro-fitment and using the existing assets with enhanced productivity.
  9. Associated systems like fume extraction, power transformer (energy intensive), water utility, ETP and heating systems are engineered for tight integration as per the process requirements.
  10. Flexible reporting that meets productivity, environment and regulatory requirements.

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4) High performance pick-and-place equipment for discrete part handling applications:

For manufacturers who handle discrete units at different stages of their manufacturing process and for industries demanding simple storage and retrieval. Unit dispensing processes have a common expectation of having simple-to-use automation, driven by user-friendly software, producing faster and maintaining positional accuracy to facilitate the core process. Simple Special Purpose Machines (SPM) that feed or load the components are one of the critical components in Automotive and Auto-component industries and also in retail industries for dispensing packed items.

Manufacturing Excellence

What are the industry expectations on Manufacturing Operational Excellence (MOE)?

In general, the most preferred way of taking decisions on investments towards increasing productivity, meeting regulatory requirements and resolving operational challenges is based on data. The concept of Big-Data or MIS and MES is evolving among the industries. Manufacturers want to leverage technology to have an integrated domain specific solution that meets the manufacturing operational excellence goals, through (plant) data-mining that enables them to take informed decisions to meet regulatory demands.

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Common Manufacturing Excellence Goals of best-in-class industries:

  • To have a “single version of the truth” that enables a synchronized and highly coordinated flow of information – eliminating traditional “silos” of data and processes to have closer visibility and control over manufacturing processes.
  • To enable paperless manufacturing that delivers paperless work instructions throughout the extended production process for rapid responsiveness and consistent deployment of processes.
  • To empower resources to meet their goals of reducing waste, controlling inventory, and lowering of cycle times while improving production efficiency, quality and customer satisfaction.
  • To deliver the right information to the right people at the right time with meaningful contextualisation to make better decisions on specific business objectives, including advanced planning, production capacity analysis, Work-In-Process (WIP), inventory turns and standard lead times.
  • To build a true foundation for an enterprise approach to quality, continuous improvement and compliance, and for consistent execution and delivery.
  • To manage all of the various inter-dependencies of production to simplify processes and enable greater collaboration by providing a single, enterprise-wide system of records.
  • To deliver a “single version of the truth” that eliminates “silos” of operations and departments, thereby enabling a synchronized and coordinated flow of information to enable tighter control over distributed manufacturing processes.
  • To empower manufacturers to meet their goals for reducing waste, inventory and cycle times to improve efficiency, quality and customer satisfaction.
  • To provide a true foundation for enterprise quality, continuous improvement and regulatory compliance for the lowest total cost.

What is in store from BASE?

Commonly applicable modular point solutions for manufacturing industries which are scalable for integrated systems.

  • Production order processing.
  • Kanban (routing as per plan with built in Poka-Yoke).
  • Automated RM stores to WIP issue for planned BOM (Picklist).
  • Online WIP tracking.
  • Productivity monitoring – Plant Efficiency Monitoring.
  • Asset Management and Disaster Recovery with change control of critical soft data of the plant.
  • Centralised Process of critical data storage and reporting.
  • Data connectivity between plant machinery and process with Enterprise System (ERP) – Management Dashboard.
  • Genealogy tracking of produced products from RM storage till FG warehousing (PI – Product Integration or Line Integration).
  • Portal based contextualising of multiple data for user driven decision making.
  • SPC/SQC quality analysis and reporting.
  • Integrated Energy Management.
  • Recipe Management System (RMS).
  • Electronic Batch Report (FDA compliance) with sequence management and audit trails.

Why BASE?

  1. We have a consultative approach to understanding the customer’s needs through close interaction with subject experts and technical consultants.
  2. We possess domain knowledge of specific industry needs.
  3. We use a mix of technical expertise in IT software technologies & applications, networking, multi-platform control software, identification technologies such as RFID, barcoding, OCR etc. and embedded control interface, all under one roof which provides a tightly integrated solution.

Our operational excellence solutions are scalable and modular with required customisation specific to industry verticals such as automotive, auto-components, tyre, consumer goods, processed food and pharmaceutical products. The solutions are available to the customers through multiples of point solution deliverables that meets productivity, quality, regulatory, environment safety, and energy efficiency requirements.

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We offer more possibilities to meet your every need.