Discover how Ecolibrium partnered with a leading global motorcycle manufacturer in India, leveraging Ecolibrium’s SmartSense to transform their Hosur facility. Explore how we enhanced operational visibility and delivered actionable insights, optimising assembly line efficiency by reduction in idle time and cycle time all powered by our advanced AI-driven decarbonisation platform.  

Outcome summary  

• Reduced assembly line idle time by 5%, boosting productivity and lowering carbon emissions by an equivalent amount. 

• Future-proofed capital expenditure (Capex) enabled a 5% increase in capacity, supporting greater efficiency and scalability for future growth. 

The Challenges 

The client, a major automotive manufacturer in India, struggled with operational inefficiencies at their plant due to infrastructure limitations and a lack of visibility into critical equipment performance. Previous vendor solutions failed to fully resolve these ongoing challenges. 

The Solution  

Ecolibrium’s SmartSense integration at a leading Indian motorcycle manufacturer transformed operations by refining data acquisition and leveraging advanced AI-ML algorithms, achieving a 5% reduction in machine idle time, substantial Capex savings, and a 5% drop in carbon emissions all without major plant expansion. Deployed at one plant to monitor multiple assembly lines and key production equipment, the solution utilized real-time amperage data for machine state differentiation, cycle time analysis, and idle time benchmarking to optimize throughput. Implemented solutions included Operational Excellence, Sustainability, Energy Management, CO2e Tracking, Overall Equipment Effectiveness (OEE), and Asset Condition-based and Predictive Maintenance (CBM/PDM), empowering the client to boost efficiency and exceed objectives through data-driven sustainability. 

The Outcome  

The initiative reduced idle time by 5% and optimized both energy use and processes, directly improving overall energy efficiency. These improvements enabled a 5% increase in production capacity without requiring additional capital expenditure. As a result, carbon emissions were also reduced by 5%.

The Impact  

Ecolibrium’s SmartSense was implemented at the Hosur facility to enhance equipment visibility and optimize assembly line operations. It replaced outdated data loggers with advanced sensor technology, providing a unified view of machinery performance and idle time. This also enabled detailed cycle time analysis and helped detect inefficiencies for targeted process improvements. 

Ready to Boost Efficiency and Cut Emissions in Your Facility?  

Harness the potential of data-driven operations with Ecolibrium’s SmartSense, engineered to elevate efficiency and sustainability at your facility. Book a demo to begin your transformation toward smarter, high-performing building management.