The differentiator of the future will not be operational efficiency alone but an ecosystem conducive to innovation. However, for manufacturers, there are more pressing challenges than the scarcity of raw materials, shortage of qualified workers, and competitive and regulatory pressures that stand in the way.

As market entry barriers continue to grow thinner, industry players are looking to retain market leadership by reducing innovation cycles and introducing new products faster than ever before. This requires realigning the existing production cycle to every engineering change − a time intensive process. The tightrope for the manufacturers is stretched further when we add external factors and risks to this mix.

Utility prices have been steadily increasing over the years—burdening operators with the task of identifying and eliminating inefficiencies, while diminishing energy consumption. Moreover, regulators are mandating compliance to exceedingly stringent emission and safety norms. It forces plant operators to spend precious hours on monitoring and auditing utility usage—keeping a close watch on workplace and employee safety compliance. It is an unavoidable yet peripheral activity vital for hedging against hazards and disruptions like fires, explosions, and injuries, which often result in wasted man-hours and loss of productivity.

With Plant Engineering as a Service (PEaaS) as the next frontier of industrial evolution, manufacturing can now focus on its core activities of product development and innovation. Apart from driving down operational expenses, it enables them to gain unprecedented visibility into processes across sites and make the most out of every dollar spent.

OVERVIEW

PLANT ENGINEERING AS A SERVICE (PEaaS)

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With manufacturers increasingly focusing on agility, responsiveness, and personalization, plants need to seamlessly and efficiently collaborate on every level—from design and prototyping to sourcing and assembly. This essentially means that plants will need to work as a “Oneplant” ecosystem that is more integrated, predictive, lean, and powered by new technology. To enable this transition, L&T Technology Services (LTTS) offers:

Intelligent Industrial Automation (IIA) – PLC-, DCS-, SCADA-, and MES-based automation for manufacturing processes and operations

Integrated Manufacturing Services (IMS) – Simulation services and tools and fixture development for improving efficiencies

Engineering Application Software – Development and deployment of engineering software applications for plant operations and automation

Engineering Analytics – Data ingestion platforms, modelling, visualization, and managed services

Mobility & Augmented Reality Applications (MARS) – Design, development, and testing services

Manufacturing Operations Management – Consulting, implementation, and support for manufacturing execution system software, tools for process and discrete industry verticals

Digital Product Lifecycle Management (PLM) – End-to-end manufacturing process digitization that extends to cover aftermarket and product sustenance services

Information management, maintenance, and material management

Enterprise asset management

Integrated Asset Performance Management (IAPM)

Document Control and Management System (DCMS)

CONNECTED PLANTS

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The process industry is largely asset heavy in terms of plant machinery and equipment. This culminates in a scenario wherein operational efficiency takes a hit owing to unstructured maintenance planning as well as poor inventory management with respect to replacement and spare availability.

Moreover, it places significant stress on the manufacturer’s bottom line, driving up CAPEX and OPEX, and diminishing Overall Equipment Efficiency (OEE). To address these challenges, LTTS provides Integrated Asset Management Services (IAMS) that complies with Health Safety and Environment (HSE) standards. This, in turn, enables real-time condition-based monitoring and predictive analytics for driving MRO activities. It also includes:

ASSET MANAGEMENT

With energy prices in a constant state of flux, plant operators across industries are struggling to optimize their water, air, gas, electricity, and steam consumption. While utility costs are largely beyond their control, reducing operating costs and overall production expenses have been identified as challenges which can be surmounted.

In this regard, LTTS provides end-to- end solutions for identifying, auditing, monitoring, engineering, deploying, and metering WAGES. Our industry experience and expertise includes:

W.A.G.E.S. SOLUTION

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LTTS has exhaustive bouquet of services and solutions designed to assist manufacturers and plant operators achieve cost efficiencies of scale. By refocusing engineering objectives on layout optimization and lean design principles, we enable manufacturers to improve plant sustainability and optimize OPEX. Utilizing our years of industry experience, we support operators with mechanical and civil engineering expertise and metric-driven decision making tools.

DISCIPLINED ENGINEERING

On-site audit, data management, analysis, and reporting

Consultation for potential energy-saving schema

Energy Conservation Measures (ECM) implementation

Plant KPI monitoring

Energy Monitoring and Metering Solutions (EMMS) design

Digitalized dashboard development for KPIs

Process engineering services including process simulation, process safety and HAZOP study, hazard prevention and protection strategy implementation, and gap analysis

Mechanical engineering services for static, rotary and packaged equipment, piping, HVAC, firefighting, and dust control

Civil, structural and architectural engineering services comprising construction detailing and documentation, steel and concrete detailing, structural stability study, and plumbing and sanitary design

Electrical engineering and instrumentation services that cover electrical system risk assessment, installation and commissioning support, SIL verification and validation, and power distribution system design

KEY DIFFERENTIATORS

Manufacturing engineering simulation reduces up to 20% of prototype manufacturing cost and 30% of build time

Augmented reality services offers up to 12% increase in productivity for a smart workforce

Integrated PLM services can reduce manufacturing process time by 25-40%

PLC, DCS, SCADA and MES-based intelligent automation for manufacturing operations improves OEE by 15%

Spare part rationalization and asset verification for reducing souring lead time, in turn diminishing downtime

Phase-based audits can identify, analyze, and evaluate energy/utility sinkholes to reduce utilization and boost operational efficiency

BENEFITS

CASES

Reengineered client’s existing plant by integrating a new assembly facility to accommodate compact tractors. Introduced the flexibility to manufacture nine variants of the product on the same line. Executed basic process planning, control planning and work instructions, takt time computation and throughput study.

Conducted structural stability study for paper manufacturing major. Inspected structural stability of the paper machine platform for existing load within seismic zone 2 and 3. Delivered insights on actual structural strength by individually designing each column and footing.

Delivered energy audit services to leading dairy company in India. Identified key energy savings potential and provided insights to save approximately 20% energy from annual budgets. Audited areas including refrigeration, HVAC, lighting, hot water generation, and compressed air.

Evaluated and consulted on the energy consumption of a waste heat recovery system. Reduced natural gas usage by 200 lb/hr and hot water boiler requirements by half. Delivered calculation sheets, process flow diagrams (PFDs), datasheets, vendor specifications, and schematics.

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About L&T Technology Services

L&T Technology Services Limited is a subsidiary of Larsen & Toubro Limited with a focus in the engineering services space, partnering with over 50 Fortune 500 companies. A leading pure-play Engineering, Research and Development services company, we offer design and development solutions through the entire product development chain, across various industries such as Industrial Products, Medical Devices, Transportation, Telecom & Hi-tech, and the Process Industry. We also offer solutions in the areas of Mechanical Engineering Services, Embedded Systems & Applications, Engineering Process Services, Product Lifecycle Management, Engineering Analytics, Power Electronics, Machine-to-Machine (M2M), and the Internet-of-Things (IoT).

Date of creation: 07/08/2017 Valid until: 07/08/2018For External Distribution

Technology Leader Zinnov GSPR 2015

Deep domain experience and expertise in providing end-to-end solutions with flexible engagement models and commercial innovations

Proactive approach towards complying with sustainability, health, safety, and environmental regulations

Comprehensive support for engineering and implementation

Extensive global reach with a geographically distributed resource base

Close alliances with Cisco, Rockwell, OSI

Recognized by Gartner and ARC Advisory Group