Manufacturing • Industry 4.0 • Complete Transformation

Dutch Manufacturing Giant: Industry 4.0 Complete Transformation

How we transformed a 150-year-old family manufacturing company into an Industry 4.0 leader, achieving 35% operational efficiency gains and €50M cost savings in 18 months.

35%

Operational Efficiency

€50M

Annual Cost Savings

-40%

Carbon Footprint

The Industry 4.0 Challenge

150-year heritage meets digital disruption. Brexit supply chain crisis forces complete transformation.

Legacy Operations Crisis

Critical transformation needed

Company Heritage150 years old
Annual Revenue€2B+
Global Workforce5,000+ employees
Manufacturing Sites12 facilities

Critical Business Pressures

• Brexit supply chain disruption costing €2M/month
• Industry 4.0 competitors gaining 20% cost advantage
• EU carbon regulations requiring 40% emission reduction
• Manual processes limiting production agility
• Siloed IT systems preventing data-driven decisions

Technical Challenges

• 50+ legacy systems with no integration
• Zero real-time production visibility
• Manual quality control processes
• Energy waste from inefficient operations
• No predictive maintenance capabilities

Complete Industry 4.0 Transformation

All 5 LobiDigital services integrated for comprehensive transformation

📡

IoT Data Streaming

Messaging & Streaming

10,000+ sensors → real-time production intelligence

☁️

Cloud-Native Operations

DevOps & Cloud

Zero-downtime deployments across 12 facilities

🏭

Smart Factory Architecture

IT Consulting

Enterprise architecture for Industry 4.0 readiness

📊

Predictive Analytics

Monitoring & Observability

AI-powered dashboards predicting equipment failures

🛡️

24/7 Smart Operations

Managed Services

Critical manufacturing systems with 99.9% uptime SLA

🌱

Sustainability Platform

Integrated Solution

Real-time carbon tracking and optimization

Technology Foundation

Kafka EcosystemApache SparkKubernetesPrometheus/GrafanaTerraformGitLab CI/CDTensorFlowTime Series DatabasesEdge ComputingDigital TwinsOPC-UA IntegrationMQTT Protocol

18-Month Transformation Timeline

1
Months 1-6

Foundation & Quick Wins

IoT sensor deployment, data lake setup, pilot production line

2
Months 7-12

Scale & Integrate

All facilities connected, predictive maintenance, quality automation

3
Months 13-18

Optimize & Innovate

AI-driven optimization, carbon tracking, supply chain integration

Industry 4.0 Leadership Results

From traditional manufacturing to digital industry leader

35%

Operational Efficiency

Predictive maintenance + automation

€50M

Annual Savings

Cost reduction + efficiency gains

-40%

Carbon Reduction

Energy optimization + waste reduction

99.2%

Quality Score

AI-powered quality control

Return on Investment

8 months

Payback Period

€15M

Project Investment

4.2x

3-Year ROI Multiple

Operational Excellence

• Predictive maintenance preventing 95% of breakdowns
• Real-time quality control reducing defects by 60%
• Automated production scheduling optimizing throughput
• Energy consumption optimization saving €8M annually
• Supply chain visibility reducing inventory by 25%

Strategic Advantage

• Industry 4.0 leader in traditional manufacturing
• EU sustainability compliance ahead of regulations
• 25% faster time-to-market for new products
• Digital twin technology enabling virtual testing
• Platform for AI-driven innovation initiatives

Ready for Your Industry 4.0 Transformation?

All 5 services integrated for complete digital manufacturing transformation.