{"id":7605,"date":"2022-08-10T13:28:00","date_gmt":"2022-08-10T13:28:00","guid":{"rendered":"https:\/\/ttlwebprod.tatatechnologies.com\/uncategorized\/launch-new-plants-faster-at-a-lower-cost-thats-engineering\/"},"modified":"2022-08-10T13:28:00","modified_gmt":"2022-08-10T13:28:00","slug":"launch-new-plants-faster-at-a-lower-cost-thats-engineering","status":"publish","type":"post","link":"https:\/\/ttec-web-dev.tata.thef.net\/in\/success-stories\/launch-new-plants-faster-at-a-lower-cost-thats-engineering\/","title":{"rendered":"Launch new plants faster, at a lower cost. That\u2019s engineering."},"content":{"rendered":"\n<div class=\"wp-block-create-block-copy-block-two py-5\"><div class=\"container px-6\"><svg class=\"w-full mb-7\" version=\"1.2\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"1536\" height=\"10\"><defs><clipPath clipPathUnits=\"userSpaceOnUse\" id=\"cp1\"><path d=\"M0-1h1919.71v12.66H0z\"><\/path><\/clipPath><\/defs><g id=\"Clip-Path\" clip-path=\"url(#cp1)\"><g id=\"Layer\"><path class=\"text-purple s0\" d=\"M.5 11.5 5.2-.8M7.5 11.5 12.2-.8M14.5 11.5 19.2-.8M21.5 11.5 26.2-.8M28.5 11.5 33.2-.8M35.5 11.5 40.2-.8M42.5 11.5 47.2-.8M49.5 11.5 54.2-.8M56.6 11.5 61.2-.8M63.6 11.5 68.3-.8M70.6 11.5 75.3-.8M77.6 11.5 82.3-.8M84.6 11.5 89.3-.8M91.6 11.5 96.3-.8M98.6 11.5l4.7-12.3M105.6 11.5l4.7-12.3M112.6 11.5l4.7-12.3M119.7 11.5l4.6-12.3M126.7 11.5l4.7-12.3M133.7 11.5l4.7-12.3M140.7 11.5l4.7-12.3M147.7 11.5l4.7-12.3M154.7 11.5l4.7-12.3M161.7 11.5l4.7-12.3M168.7 11.5l4.7-12.3M175.8 11.5l4.6-12.3M182.8 11.5l4.6-12.3M189.8 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md:grid-cols-2 mb-7\"><h3 class=\"font-header text-4xl md:text-5xl pb-5 -mt-1 text-primary pr-5\"><strong>Challenge<\/strong><\/h3><div><div class=\"copy-block-two-blurb text-lg\"><p>The customer wanted to deploy virtual commissioning tests in their manufacturing systems and associated control programs through simulation conducted virtually in a lab setting before the actual deployment in a plant. They were looking to achieve early detection and correction of errors generated during engineering, especially in controller programming. The customer chose Tata Technologies, a global leader in digital engineering solutions for the manufacturing industry, to design and develop the concerned system framework.<\/p><\/div><\/div><\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-create-block-copy-block-two py-5\"><div class=\"container px-6\"><svg class=\"w-full mb-7\" version=\"1.2\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"1536\" height=\"10\"><defs><clipPath clipPathUnits=\"userSpaceOnUse\" id=\"cp1\"><path d=\"M0-1h1919.71v12.66H0z\"><\/path><\/clipPath><\/defs><g id=\"Clip-Path\" clip-path=\"url(#cp1)\"><g id=\"Layer\"><path class=\"text-purple s0\" d=\"M.5 11.5 5.2-.8M7.5 11.5 12.2-.8M14.5 11.5 19.2-.8M21.5 11.5 26.2-.8M28.5 11.5 33.2-.8M35.5 11.5 40.2-.8M42.5 11.5 47.2-.8M49.5 11.5 54.2-.8M56.6 11.5 61.2-.8M63.6 11.5 68.3-.8M70.6 11.5 75.3-.8M77.6 11.5 82.3-.8M84.6 11.5 89.3-.8M91.6 11.5 96.3-.8M98.6 11.5l4.7-12.3M105.6 11.5l4.7-12.3M112.6 11.5l4.7-12.3M119.7 11.5l4.6-12.3M126.7 11.5l4.7-12.3M133.7 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11.5l4.7-12.3M1521.5 11.5l4.7-12.3M1528.5 11.5l4.7-12.3M1535.5 11.5l4.7-12.3\" style=\"stroke:#350FA2\"><\/path><\/g><\/g><\/svg><div class=\"copy-block-two md:grid grid-cols-1 md:grid-cols-2 mb-7\"><h3 class=\"font-header text-4xl md:text-5xl pb-5 -mt-1 text-primary pr-5\"><strong>Solution<\/strong><\/h3><div><div class=\"copy-block-two-blurb text-lg\"><p>The customer faced multiple challenges in terms of plant and machinery operations, dependencies on the sequential workflow of conventional commissioning, uncertainty to ensure adherence to delivery timelines, operator safety while commissioning, inability to test various failures and disturbance scenarios, lack of flexibility in-lined with in-house capability and multiple ownerships. The Tata Technologies team implemented virtual commissioning methodology for machinery as well as plant level commissioning through a 3-phased approach using digital twin model development for virtual commissioning, followed by digital twin model testing.<\/p><p>From the Proof of Concept (PoC) phase to scaling up and implementation to diversification, the 3-phased virtual commissioning approach included designing solution architecture for emulating digital twin model of plants and equipment aligned to the real plants and equipment to monitor the on-going activities virtually from the control room. We also integrated digital twin with IIoT to collate and analyze critical parameters such as the temperature of motor bearing for predictive maintenance.<\/p><p>This was the first-ever exercise by an industry incumbent to execute virtual commissioning at the plant level. We achieved 30% savings in the commissioning cost as compared to conventional commissioning methodologies, where a day\u2019s saving is equal to ~$8 M of full production capacity. The manufacturer was able to reduce the on-site testing efforts, project lead time by 15% and overall costs and attain improved application quality, productivity &amp; working conditions.<\/p><\/div><\/div><\/div><\/div><\/div>\n\n\n\n<div class=\"wp-block-create-block-infographics pb-11 pt-5 mb-20 md:pt-8 md:pb-11\" style=\"background-color:#8468F6\"><div class=\"container\"><svg class=\"w-full mb-7\" version=\"1.2\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"1536\" height=\"10\"><defs><clipPath clipPathUnits=\"userSpaceOnUse\" id=\"cp1\"><path d=\"M0-1h1919.71v12.66H0z\"><\/path><\/clipPath><\/defs><g id=\"Clip-Path\" clip-path=\"url(#cp1)\"><g id=\"Layer\"><path class=\"\" d=\"M.5 11.5 5.2-.8M7.5 11.5 12.2-.8M14.5 11.5 19.2-.8M21.5 11.5 26.2-.8M28.5 11.5 33.2-.8M35.5 11.5 40.2-.8M42.5 11.5 47.2-.8M49.5 11.5 54.2-.8M56.6 11.5 61.2-.8M63.6 11.5 68.3-.8M70.6 11.5 75.3-.8M77.6 11.5 82.3-.8M84.6 11.5 89.3-.8M91.6 11.5 96.3-.8M98.6 11.5l4.7-12.3M105.6 11.5l4.7-12.3M112.6 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full-bleed mb-28\"><div class=\"py-16\"><div class=\"container-size grid grid-cols-2 h-[var(--cqh)] [--cqh:375px]\"><div class=\"angled-br h-full relative -mr-16 md:-mr-32\"><img decoding=\"async\" class=\"absolute object-cover w-full h-full\" src=\"https:\/\/www.tatatechnologies.com\/app\/uploads\/1_Bottom_image-3.jpg\" alt=\"\"\/><\/div><div class=\"angled-tl h-full relative bg-black pl-2 -ml-16 md:ml-0\"><div class=\"angled-tl h-full bg-white\"><img decoding=\"async\" class=\"absolute object-cover w-full h-full\" src=\"https:\/\/www.tatatechnologies.com\/app\/uploads\/2_Bottom_image-5.jpg\" alt=\"\"\/><\/div><\/div><\/div><\/div><\/div>\n","protected":false},"excerpt":{"rendered":"<p>The customer is the world\u2019s second-most geographically diversified steel producer. Their operations are fully integrated \u2013 from mining to the manufacturing and marketing of finished products. For a new manufacturing plant, the customer wanted to minimize construction costs and reduce the manufacturing errors \u2013 even before the plant was built.<\/p>\n","protected":false},"author":8,"featured_media":6265,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"inline_featured_image":false,"footnotes":""},"categories":[79,80,120,84,108,85,132],"tags":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v20.4 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Launch new plants faster, at a lower cost. That\u2019s engineering. - Tata Technologies<\/title>\n<meta name=\"robots\" content=\"noindex, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Launch new plants faster, at a lower cost. That\u2019s engineering. - Tata Technologies\" \/>\n<meta property=\"og:description\" content=\"The customer is the world\u2019s second-most geographically diversified steel producer. Their operations are fully integrated \u2013 from mining to the manufacturing and marketing of finished products. 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