Godrej & Boyce Mfg. Co. Ltd. (G&B) has been contributing to India’s economic progress since its establishment in 1897.
G&B, known for its exceptional engineering and innovative spirit, is part of the Godrej Group, which generates a revenue of USD$4.1 billion. The company operates across 10 different industries, offering a diverse range of products and services, from custom engineering solutions to consumer goods, appliances and furniture.
“Our products and services positively impact the lives of one-third of India’s population - and, through our overseas subsidiaries and joint ventures, we serve 1.1 billion customers across five continents,” says Nitin Patil, General Manager of Manufacturing at Godrej Precision Engineering and Global Process Owner of Maintenance.
The challenge
The scale and diversity of activities made it difficult for G&B to track and maintain more than 15,000 assets across its 14 business units. “We had an application that had been developed in-house to coordinate maintenance activities, but it did not allow us to track asset data with the granularity we wanted. In addition, extracting maintenance analytics, KPI information and reports was done manually, and it took a lot of time. Last but not the least, it was not connected to our ERP or our spare part inventory, ” Nitin Patil says. A key objective of implementing a new asset management solution was to streamline the maintenance processes across a diverse range of assets, including manufacturing plants, facilities and fleets. The solution should be able to plan, track and manage maintenance in every vertical in real-time.
The company also saw opportunities to use AI and machine learning to cut machine downtime, sharpen decision-making and gain greater agility. To capitalize on these opportunities, they required a best-in-class solution that could easily connect to third-party systems and deliver the benefits associated with Industry 4.0 and Robotic Process Automation (RPA).
The solution
The four key reasons why G&B selected Attune EAM:
Attune EAM offers real-time monitoring and reporting capabilities, allowing G&B to track the performance of its assets and make more informed decisions
It provides a common solution for all business verticals, with the flexibility to address the needs of various business units, making it an ideal solution for G&B’s diverse operations
Its advanced capabilities drive a more effective use of resources and help reduce operational costs
Its uptime is higher than traditional maintenance applications
Attune EAM’s intuitive user interface was also a decisive factor, Nitin Patil explains. “The project involved the implementation of Attune EAM for over 2,000 people across 35 distinct locations, so ease of use was a must-have. We were very pleased to see that users could become proficient with the software within a couple of weeks”.
Today, Attune EAM has been fully implemented by Octave’s implementation partner Godrej Infotech Ltd. and is used to manage over 150,000 assets, 1.5 million part references, 95,000 work orders per year and 125,000 documents. Attune EAM is being used in all businesses of G&B effectively to carry out day-to-day maintenance activities.
The platform is integrated with various systems, including the company’s ERP, MES and CRM systems, as well as its in-house customer request application.
With such a massive inventory, the shift was a significant undertaking. But Octave’s support with implementation, migration and training helped G&B to successfully deploy its new platform in just two months. “Octave’s domain experts and professionals played a critical role in the success of our project. The support they provided with project delivery and handover, as well as after the go-live, was outstanding, ensuring a successful deployment and a smooth transition.”
This Equipment Cannibalization Work Order is custom developed for Godrej & Boyce and gives them the opportunity to cannibalize useful and critical parts from equipment that is about to be decommissioned, helping reduce inventory cost and resources.
Key results
Attune EAM has sharpened how G&B tracks and manages assets across 14 business verticals.
One of the most notable improvements has been the ease of searching inventory and gaining a full view of all stock across all locations. This has allowed better decision- making regarding purchases, repairs and renewals. The system is also highly scalable and adaptable, making it straightforward to track and manage all assets.
With complete access to all assets, the company is able to maintain appropriate inventory, and make informed decisions regarding equipment updates or upgrades. The system also tracks uptime, mean time between failures (MTBF) and mean time to repair (MTTR) which allows the company to improve its asset uptime from 60% to more than 95%. As a result, inventory costs were reduced by 45% and effective labor utilization was improved by 70%.
In the years to come, Attune EAM will continue to support the company’s future growth and mission to delight over a billion customers worldwide.
