ALTEN India was approached by a global leader in the beverage industry, operating concentrate production facilities across 19 countries, to support their digital transformation journey. Known for its scale and commitment to operational excellence, the company sought to enhance production planning and execution – moving from reactive operations to intelligent, data-driven automation. The goal was to improve visibility, streamline decision-making, and bring greater agility to its global manufacturing ecosystem through scalable AI solutions.

Challenge: The client faced a critical challenge: lack of real-time visibility into production order (PO) progress. This gap resulted in inaccurate forecasting, undetected bottlenecks, inefficient manual scheduling, and complications in batching due to unknown route deviations and unclear critical paths. Without timely, actionable insights, the company struggled to maximize throughput, minimize downtime, and respond proactively to disruptions.

Solutions: ALTEN developed and deployed an IIoT-powered predictive platform to modernize the client’s production operations. The solution unified data streams from MES, machines, and sensors across all sites. Python-based regression models were used to predict PO completion times in real time, accounting for variables such as machine health, stock availability, and operator performance.

For complex batching operations, the system dynamically tracked process flows and flagged route deviations to enhance forecasting precision. A responsive, Angular-based dashboard gave operators and planners real-time production tracking, visual alerts, and delay diagnostics. These insights were directly integrated into the client’s scheduling system to enable dynamic rescheduling and better resource allocation.

Benefits: 

• Improved Forecasting Accuracy through real-time PO completion predictions
• Reduced Downtime with early issue detection
• Increased Throughput via optimized scheduling and resource allocation
• Empowered Operations Teams with intuitive, actionable dashboards
• Scalable Architecture for deployment across multilingual, multi-site environments