Digitalization
Transforming industries with cutting-edge digital solutions
Project Objective
🔍 Project Overview
A manufacturing plant sought to transition from manual, disconnected processes to a fully digital operating model. The challenges included layout inaccuracies, lack of plant visibility, and frequent rework due to design-installation gaps.
Under a Build & Operate model, Cognition IES took full ownership — from digital engineering setup to real-time operational monitoring — delivering a live digital twin ecosystem and ongoing operational support.
🎯 Objective
To build and operate a fully digitized manufacturing environment by integrating physical plant data with real-time digital intelligence — enhancing accuracy, reducing downtime, and enabling predictive operations.
👷Key Roles Deployed
To support build, validation, and continuous operations, the following expert roles were staffed:
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Process Lead: Oversaw process design and validation, ensuring alignment with operational requirements and project specifications.
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Structural Design Engineer: Designed and validated structural components, ensuring compliance with engineering standards and plant layout requirements.
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Piping Design Engineer: Developed and validated piping designs, ensuring integration with the overall plant layout and operational efficiency.
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AVEVA – E3D & PCM Tool Experts: Utilized AVEVA E3D and PCM tools to create and manage 3D models, supporting design conformity and digital twin operations.
These professionals played a crucial role in plant layout validation, design conformity, and 3D model creation during the build phase, and provided continued engineering oversight for digital twin operations.
🛠️ Build & Operate Model Approach
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Digital Engineering Deployment: Laser scanning, 3D model generation, and as-built validation.
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Domain-Specific Role Allocation: Placement of tool experts and design engineers across disciplines.
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Digital Twin Enablement: Layering of applications to create a responsive operational environment.
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Real-Time Operationalization: Dashboards, alerts, and proactive monitoring rolled out across teams.
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Sustained Operations: Ongoing support for optimization, upgrades, and training.
💡 Key Results & Outcomes
- ⦿Improved Accuracy: 3D validation reduced layout deviations drastically, saving hours in installation rework.
- ⦿Operational Efficiency: Downtime was minimized through real-time alerts & predictive maintenance insights.
- ⦿Energy Optimization: Monitoring & simulation helped reduce energy consumption per unit produced.
- ⦿Scalable Infrastructure: The platform is future-ready, adaptable for upcoming automation and robotics integration.
- ⦿Better Visibility: Stakeholders can now access real-time status, performance metrics, and alerts via a centralized dashboard.
| Metric | Before | After |
|---|---|---|
| Layout Error Rate | ~8% | less than 2% |
| Production Downtime | 12hrs/month | less than 3hrs/month |
| Rework due to fit issues | 5+ incidents/month | 0 incident |
💡Technologies Used
- ⦿3D Laser Scanning Equipment: For precise spatial data acquisition.
- ⦿AI-Powered Analysis Tool: Validate & analyze scan data against design specifications.
- ⦿Digital Twin Platforms: Creating & managing intelligent digital replica of the facility.
- ⦿Dashboard and Visualization Tools: For real-time monitoring and analytics.
🔄Client Feedback
This digital transformation has fundamentally changed how we operate. We now have a living, breathing model of our plant that helps us plan better, run smoother, and grow smarter.
— Head of Operations, Confidential Client