March 17 2011 · Sustainable Mfg enabled by IT –Wipro’s Sustainability Services Focus Area...

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


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)


• 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


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


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


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


•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


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


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


Well on their way to targeted energy reduction of 12% YoY

Thank You

Sanjeev R

Sustainability Practice Head, Wipro Technologies

[email protected]

© 2011 Wipro Ltd - Confidential

March 17 2011 · Sustainable Mfg enabled by IT –Wipro’s Sustainability Services Focus Area...

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