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Sustainable Manufacturing & Competitiveness –Is there a tradeoff?
March 17th 2011March 17 2011
Sanjeev RSustainability Practice HeadSustainability Practice Head
Manufacturing & Hi-Tech solutions Wipro Technologies
© 2011 Wipro Ltd - Confidential
Sustainability – Choice or Imperative?
More of Social Philosophy and belief
More of Social
Responsibility than a
business objective
C h
Cost efficiency
through sustainable
operationsCost outweighs
benefit
Compliance mandate
Sustainability as a
driver of innovation
N B i M d lNew Business Models
© 2011 Wipro Ltd - Confidential2 © 2011 Wipro Ltd - Confidential2
Moving from Traditional to Sustainable Mfg
Sustainable Manufacturing• Sustainability criteria in product
feasibility and future product d l
• Sustainable Product Design & D ldevelopment
• Local Sourcing & supplier compliance criteria in procurement
• Energy & Resource Efficient
Development• Sustainable Procurement• Sustainable Manufacturing System
Design• Efficient Manufacturing Operations
across plants and support officesgyFloor planning & Placement
• Energy efficient job & shift scheduling
• Optimized Manufacturing Execution for reduced energy &
across plants and support offices• Sustainable Supply Chain Modeling• End-of-Life Recovery Management
Traditional Manufacturing
Distribution
resource consumption
• Supply Network Optimization• Transport Energy and
Emission Modeling
• Maximize recovery, reuse &
PlantsInbound warehouse
CustomersLogistics Providers
OutboundWarehouse
R&D Centers
Suppliers
Maximize recovery, reuse & remanufacture for end-of-life products
• Green Product Positioning• Eco-Labeling, Certifications
© 2011 Wipro Ltd - Confidential3 © 2011 Wipro Ltd - Confidential3
Retailers
Repairs Centre
Logistics Providers
Planners
• Design for Environment (DfE)
Design (PLM) Manufacturing (MES/PES)• Real time Shop floor data
Logistics (ERP/SCM)• Supply Network Optimization
Enablement of Sustainability Solutions across the Manufacturing Value Chain
• Bill of Substance (BOS)• Environmental Product Lifecycle
Analysis
• Real time Shop floor data• 2-Way Smart devices and
meters • Remote monitoring • Building Mgmt Systems
• Supply Network Optimization• Collaborative Logistics• Globalization vs. Localization
business case decisions• Virtual Packaging Formulations
R&D
Distribution Centers
Info Flow
Goods Flow
PlantsInbound h
CustomersLogistics ProvidersOutboundSupplierswarehouse
Retailers
Warehouse
Repairs
Logistics ProvidersPlanners
Repairs Centre
• IT-enabled Green Procurement• Supplier Profiling & assessment • End of Life Recovery f c m nents
Procurement (BPO)Aftermarket (PLM/SCM)
Planning (SCM)
© 2011 Wipro Ltd - Confidential4 © 2011 Wipro Ltd - Confidential4
• Supplier Profiling & assessment• Supplier Compliance Mandates• Make vs. Buy decisions• Local Sourcing
• End-of-Life Recovery of components• Remanufacture• Waste Tracking & Management
Demand planning and supply network design
Wipro’s own approach to Sustainability
Remodel operations (reduce, recycle & offset) to reach neutrality/ surplus in the four identified areas (energy, water, waste & biodiversity)
Ecological SurplusOrganization
1
Build a portfolio of investments that will open new opportunities of sustainable business
Associate/partner with suppliers, NGOs, government, forums (regional, national
BusinessInvestments2
Actively Engage 3 & global), etc, as part of larger sustainability initiatives in energy, water, waste & biodiversity
Establish, act and disclose on a framework of sustainability-centered measuring & reporting based on GRI G3 guidelines
Actively Engage our stakeholders
3
TransparentReporting4
& reporting based on GRI G3 guidelines
Assess risks to Wipro arising from climate change & ecological degradation; Publish the risk-mitigation plan
Reporting
Risk Planning &Mitigation
5
© 2011 Wipro Ltd - Confidential5 © 2011 Wipro Ltd - Confidential5
Sustainable Mfg enabled by IT – Wipro’s Sustainability Services
Focus Area Solutions Services
Strategy Services Consulting - Green strategy, Benchmarking & Roadmap for Assessment & Implementation
ComplianceEHS SolutionsCarbon tracking & reportingMaterial Compliance reporting
Advisory & ConsultingCompliance Monitoring, Data Analytics, Mining & IntelligenceReport Generation, Auditing and AssuranceS.M.A.R.T
E i S i bili
OperationsEnterprise Sustainability Intelligence, Reporting and Record Management Platform
Consulting, Assessment & CertificationPlant/Facility Modeling, Data Integration, Intelligence, ReportingReal time MonitoringManaged Energy ServicesAlternate Energy Recommendations & Implementations
Enterprise Sustainability Platform
Data integration Alternate Energy Recommendations & Implementations
ProductsProduct based Energy and Resource Visibility Platform
Design for Environment on top of PLMProduct Data IntegrationLifecycle Impact Analytics, Data Mining & Intelligence
gReportingIntelligenceOptimization
Supply ChainSupply Chain Sustainability Monitoring and ReportingSupplier Material Compliance Platform
GreenSCOR ConsultingSC Compliance, Data Analytics & Risk Monitoring
Performance management
© 2011 Wipro Ltd - Confidential6 © 2011 Wipro Ltd - Confidential6
IT Infrastructure Hosted Cloud-based datacentersDatacenter Monitoring & OptimizationVirtualization ServicesCloud Migration Services
SMART: Sustainable Manufacturing Analytics & Reporting ToolkitAn Enterprise Sustainability Platform
Energy Emissions Resources Waste Recovery
Operations Compliance Product In & Out Bound
FacilitiesMfg PlantsOfficesDatacenters
Material ComplianceMandated ComplianceVoluntary DisclosuresAudit Support
Product ComplianceProduct based Root Cause AnalysisActivity based Costing
Suppliers/VendorsLogisticsWarehouses/DCsSourcing AnalyticsR L i ti
pp y gReverse Logistics
Aggregate, Analyze and derive Intelligence on your Sustainability
Plant Manager
S l
Integrate Sustainability parameters into
f
Product Manager
Measure, Monitor all your organization’s Sustainability Parameters
CSOyour Sustainability Status
Highlight hotspots and trends of excess utilization for improvement f
Monitor and manage Supplier material compliance
Supply chain Mgr
the design of the Product
Compare “As-designed” and “As-Manufactured” BOMs drive
Report in Automated and transparent fashion to all Internal and Eternal Stakeholders
Compliance Manager
© 2011 Wipro Ltd - Confidential7 © 2011 Wipro Ltd - Confidential7
Set targets and Track Sustainability Performance
focusUse pre-defined geography specific templates to align to GreenSCOR
changeEnable and Aggregate various Sustainability efforts across the organization
SMART: The Underlying Enabling Platform
Visualization
• Trending Analysis• View and drill down usage
Decision Support System
• Resource requirement Forecasting
• Pre‐configured and custom Sustainability reporting
Reporting Performance Management
gand cost Analytics
• Product‐wise Root Cause Analysis
• Highlighting Environmental Hot‐spots within the System
Forecasting• Projections on Business‐As‐Usual Scenario
• What‐if Scenario Analysis• Benchmarking and Comparison
• User Configurable KPI Dashboard
• Role Specific Views• Target Setting• Display of performance against the Targets set
y p g• One Click generation of Compliance reports
• Automatic Collation and aggregation of data from various sources
• Geo‐specific templatesA dit T ki & S t
Modules Data Management
• Audit Tracking & Support
Compliance Operations ProductsSupply Chain• Sustainability Master Data Mgmt.• Mfg Industry based Data Modeling
ERP Systems•HR Data•Financials
MES Systems•Daily Production Data
PLM Systems•“As-designed” BOM Management
Smart Meters•Instantaneous energy usage
Supplier Management Systems
© 2011 Wipro Ltd - Confidential8 © 2011 Wipro Ltd - Confidential8
•Facility information•BOM data•Manufacturing Process
•Scrap Data•Rework Data•Component Reuse Data
•Material Compliance
•“As-designed” Manufacturing Process
•Water utilization•Emission produced•Specific source used per resource
•Compliance reports•Green channel Suppliers list
SMART - Our Experience
© 2011 Wipro Ltd - Confidential9 © 2011 Wipro Ltd - Confidential9
Our Experience -Operations Excellence for Wipro
Wipro chose SMART to implement an enterprise wide program on Energy/Water and Waste Management with the basic objective of reduction in Energy & Resource Costs and optimization of
existing investment in utility infrastructure.
SMART ImplementationScope of Services
Analyze & identify power/water consumption pattern & trends.
Implemented energy/water and waste analytics across all India locations
Set targets for reduction QoQ and YoY.
Develop methods to optimize the power and water consumption and waste generation.
Implement the solutions & monitor progress
Action plans based on Power consumption distribution, pattern and hotspots
Based on these findings, the client took the following actions and solutions
against set targets. Consolidation mechanism for servers based on utilization rates.
Redesigning of UPS/Server room layouts.
Power control scripts for Desktops & Laptops Power control scripts for Desktops & Laptops
Dashboards & Performance Mgmt
© 2011 Wipro Ltd - Confidential10 © 2011 Wipro Ltd - Confidential10 © 2011 Wipro Ltd - Confidential10
Trending, Comparison and Benchmarking Target Setting
Drill Downs
Our Experience -Operations Excellence for Wipro
27%Achievements
Total energy saved per week > 27%
Savings 25,000 it
gin power consumption at model facility
units
95 12%95%
50
Weekend power consumption by large labs reduced
12% Saving
© 2011 Wipro Ltd - Confidential11 © 2011 Wipro Ltd - Confidential11 © 2011 Wipro Ltd - Confidential
50%labs reduced
in energy for the location
Our Experience -Energy Sourcing & Usage Optimization for a Global Aerospace Major
Our Client’s Facilities team chose SMART to pilot the automation of process of collection & reporting of Steam usage for its US based plant.
Multi-dimensional dashboards on Equipment Power and Steam Usage.Energy Performance trends
and benchmarking across years
S P i d
© 2011 Wipro Ltd - Confidential12 © 2011 Wipro Ltd - Confidential12
Steam Parameter comparison and trending on a supplier-to-supplier basis.
Our Experience -Implementation Projects in India
Activity Based Costing and Visibility for one of the largest independent Hydraulic Cylinder manufacturer in the world
Process level Visibility into energy usage & costs on a per unit product basis
Emission, Waste and Water footprint analytics & reporting
Manufacturing Process Efficiency Analytics
Energy Analytics and Optimization for a large diversified
Manufacturing Process Efficiency Analytics
gy y p gbattery manufacturer
Energy usage dashboards and trending
Predictive and Preventive Analytics on energy data using a combination of Plant Utilization, Energy Loss and Production Quantity
© 2011 Wipro Ltd - Confidential13 © 2011 Wipro Ltd - Confidential13
Well on their way to targeted energy reduction of 12% YoY
Thank You
Sanjeev R
Sustainability Practice Head, Wipro Technologies
© 2011 Wipro Ltd - Confidential