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Introduction

 

India has become the location of choice for Global Capability Centres (GCCs). Today, more than 1,000 multinational corporations have based their operations here to leverage essentially a deep pool of highly skilled yet cost-optimised talent. These centres were originally established primarily for cost savings and talent arbitrage, allowing organizations to streamline business functions while enjoying substantial financial benefits. However, against the backdrop of increasing dynamism and competitiveness in today’s global business environment, GCCs will increasingly move beyond just being a pure cost or resource centre. They then move along a maturity curve, from sites delivering operational efficiency to excellence centres driving innovation, quality, and strategic value.

As GCCs mature up the curve, the demand for advanced strategies and methodologies has grown. It is in this background that Software Craftsmanship assumes importance—this movement focuses on ensuring strong software development practices and quality with an emphasis on continuous learning. In this context, it becomes imperative that GCCs recognize how a deep technology partnership with an outsourced software product development company can make a critical difference in their evolution. The partnerships will help GCCs tide over the mounting operational challenges and deliver value to the entities.

This article discusses the key challenges that Indian GCCs face, the key role that software craftsmanship will play in helping GCCs get past their challenges, and why outsourced product development services that are well-versed in software craftsmanship practices are urgent for GCCs to reach their full potential.

Source: Deloitte

Key Challenges Faced by Indian GCCs

 

Scaling Teams and Innovation

As GCCs mature and take on more responsibilities, scaling their teams quickly becomes necessary. However, scaling a team is not just a question of hiring more people; it has much to do with creating an environment in which innovation and creativity can flourish. One should balance the need to scale by continuing to have a culture of innovation, which is quite hard to maintain when the organization expands.

Maintaining Code Quality and Consistency

With the increasing complexity of projects handled by GCCs today, quality and consistency become matters of uppermost importance:

• Low-quality code has 15 times more defects than high-quality code.
• Fixing issues in low-quality code takes 124% more time on average.
• Maximum cycle times for issue resolution in low-quality code are 9 times longer. (The ACM Digital Library)

Robust development practices, such as code reviews, testing, and documentation, should be followed to ensure that produced code is of high quality and can be easily maintained.

Managing Distributed Teams

More often than not, GCC teams are based in different cities, countries, or even continents. Distributed teams could be a hassle in terms of communication, collaboration, and culture. Clear channels of communication should be defined, providing the relevant tools and fostering an open and transparent climate for the distributed teams to work collaboratively within GCCs.

Bandwidth Issues

Particularly in earlier phases of maturity, GCCs may overstretch their resources, handling too many projects or responsibilities without sufficient staffing or expertise. As teams face soaring demands, this results in burnout and reduced productivity. They may need to consider tie-ups with outsourcing software development companies for help in administering the workload.

Accelerating Digital Transformation and Adopting New Tools

GCCs need to keep pace with the pipeline of new technologies and tools constantly to maintain competitive strength in delivering quality service to their parent organizations. Meanwhile, the pace of change has probably never been more complex to embrace new technologies, particularly so in areas like IoT, Gen AI, AR/VR, and Digital Twin, which are relatively new and keep evolving even now. GCCs must instill a culture of continuous learning and experimentation and be willing to invest in training and development to ensure the necessary competencies within their ranks with the required skills and knowledge for successful adoption.

The Role of Software Craftsmanship in Addressing GCC Challenges

 

What is Software Craftsmanship?

Software craftsmanship is a philosophy and approach to software development that focuses on developers’ coding skills and on how good the quality of the software produced is. It’s a response to a perceived general decline in software development standards, wherein, more often than not, speed and cost triumph over quality and maintainability.

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Introduction

Immersive technologies like augmented reality (AR) and virtual reality (VR) have been around for a while now. In that time, how they are viewed by enterprises has also evolved. In the early days, it was believed that these technologies were best suited for creating engagement and delivering entertainment. Over time, the applications grew in areas like learning and training, customer immersion and engagement, and field service. As the applications multiplied, so did the value they delivered in the utilities sector. Let’s look at how these technologies have become embedded into various functions and workflows in the utilities sector and how their scope and scale are expanding.

The use of AR/VR systems in the utilities sector is quite common in areas like:

• Maintenance operations
• Worker safety
• Employee training
• Remote assistance

However, that is not all. By combining AR/VR with digital technologies like AI, IoT, and Digital twins, we are now looking at more “exciting” possibilities in the future in areas previously untouched by these innovations. For instance, inspecting telecom towers:

1. Powered by AI and computer vision, “intelligent” drones can inspect and capture footage of cell towers.
2. Next, the application generates a real-time digital twin of the physical telecom tower.
3. Using AI-powered algorithms, digital twins then detect a potential issue with the telecom infrastructure.
4. Using an AR/VR representation, maintenance teams can overlay the digital twin over the physical tower to pinpoint the exact location of the problem.
5. Based on these insights, telecom maintenance teams can quickly make the right decision on how to fix the problem.

Let’s explore further and look at how the utility sector can get “smarter” with a combination of AR/VR, AI, IoT, and Digital twins.

1. Transforming GIS with IoT and Generative AI

For years, geographical information systems (GIS) have been efficient at capturing and rendering geographical data. When combined with digital twins, GIS can effectively enrich digital models with geographical insights. Further, by integrating IoT sensors, GIS can enable a real-time data feed for the digital twins.

For example, GIS can provide critical geographical data to digital twins – using digital replicas of a smart city. This data includes real-time traffic and weather data.

Generative AI models can amplify GIS capabilities by analyzing real-time data and performing predictive modeling to improve decision-making capabilities. This capability is crucial in emergencies that require quick, smart responses.

To add to the mix, an AR/VR-enabled system (integrated with the digital twin) allows users to “virtually” interact with the digital twin simulation. This rich and immersive experience supports a “smart” decision-making process.

Here are some benefits of implementing this powerful solution:

• Enhanced asset management through real-time geographical data and equipment condition.
• Faster incident response by field service teams with real-time data insights – augmented by AI and immersive technologies.

2. Managing Water utilities with AI, Digital Twins, and Immersive technology

In the face of growing water demand, water supply utilities are unable to cope due to their ageing infrastructure. Digital twins can potentially transform water management through efficient and sustainable practices. As an example, digital twins can replicate the entire water supply system, distribution networks, and water treatment facilities.

Further, AI-powered algorithms can analyze real-time data from water sensors and provide insights into:

• Supply performance
• Maintenance requirements
• Various operations

Another exciting use case is in water infrastructure planning and maintenance. With digital twins, water utility companies can “visualize” the impact of any infrastructure upgrade or modification. Additionally, by using AR/VR-enabled immersive experiences, stakeholders can improve their decisions related to water management.

3. The use of mixed reality in utility field services

Essentially, mixed reality is the convergence of the physical and digital worlds, encompassing multiple technologies including AR and VR. Mixed reality (MR) has the potential to transform field service operations in utility companies. For instance, it offers benefits in the installation and maintenance of utility systems like solar grids, water pipes, and telecommunication devices.

Here are a few benefits of MR in the domain of field service operations:

• Remote diagnosis of utility assets, thus saving both travel time and expenses.
• Improved work efficiency for field service technicians – with real-time access to user manuals, maintenance-related instructions, and troubleshooting guides.
• Faster inspection of remote utilities, thus improving productivity and customer satisfaction.

4. Energy sustainability with AR/VR

Empowering sustainability is now a growing mantra in utility companies. Through public engagement and education, AR and VR technologies can contribute to improving sustainability. For instance, the renewable energy sector can harness the power of immersive technologies to:

• Create virtual models of solar panels and wind turbines.
• Create visual representations of how renewable systems generate energy.
• Highlight the problem of resource depletion and climate change.

Here are some of the possible applications of AR/VR in renewable energy:

1. Interactive learning

Through VR, young students can now visualize renewable energy systems and collaborate on their findings.

2. Simulated training

AR and VR-based simulated training can educate technicians and maintenance engineers on the working of renewable energy equipment. In “virtual” environments, they can learn how to respond to critical situations.

3. Improved system designs

In the domain of energy sustainability, AR/VR-powered immersive experiences can help product designers improve the system design and performance. With real-time interactions with virtual objects, they can visualize and plan their next renewable energy project.

Additionally, VR-enabled simulated environments can facilitate stakeholders with a virtualized walk-through of the proposed energy facility.

Role of Pratiti Technologies in Making Utilities Smarter

For a long time, the role of immersive technology like AR and  VR has largely been restricted to machine inspections and maintenance. This narrative is gradually changing to include more exciting applications in utilities like:

• Water management
• Sustainable energy
• Geographical information

At Pratiti Technologies, we recognize the future belongs to smart energy systems. We are powering digital transformation in the energy and utilities sector with our expertise in technologies like:

• Internet of Things
• AR and VR
• Digital twins

Our energy accelerators can power you forward towards digital success. Contact us today!

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Introduction

The markets are in full swing, and your firm is experiencing peak demand. Sadly, a critical piece of equipment on the factory floor malfunctioned, potentially causing a production line shutdown. Moreover, your traditional analytics , bogged down by historical data, fail to provide real-time warnings. The result? Lost productivity, delayed deliveries, and a potential safety hazard. Traditional analytics, reliant on historical data, fail to provide real-time warnings.

In today’s data-driven economy, industries such as manufacturing, banking, financial services, insurance (BFSI), energy, and healthcare swim in an ever-growing sea of data. Each sensor reading, transaction record, and patient encounter yields significant information. But the problem is extracting real-time knowledge from this data flood to make effective decisions and stay ahead of the curve. This is where artificial intelligence (AI) and real-time analytics tools come in.

The solution to this problem is in a sophisticated technology called Streaming Data on Databricks. It is your lifeline in this fast-moving data stream, allowing you to use the power of real-time analytics at scale. This means no more lost chances, only actionable insights supplied when they are most effective.

The Data Deluge: Drowning in Information, Starving for Insights

The sheer number of data produced daily is astonishing. Consider this: by 2025, it is anticipated that there will be 175 zettabytes of data worldwide. That translates to 175 trillion gigabytes, a staggering figure. This data flood includes anything from sensor data from industrial equipment, which can create terabytes every second, to social media feeds brimming with user emotion, and real-time transactions passing through financial institutions. This data has enormous potential for revealing significant insights.
Traditional analytics solutions, on the other hand, struggle to keep up with the never-ending influx of data. Businesses are inundated with information while yearning for the real-time insights required to make vital choices. Consider a manufacturing floor inundated with sensor data, but the analytics system can only analyse it in batches, typically hours after it is gathered. By the time insights are gained, it is too late to identify probable equipment failures or optimise manufacturing processes. This is the reality for many firms dealing with outmoded analytics solutions. They lack the agility to analyse data in real-time, which limits their capacity to respond to changing situations and seize ephemeral chances.

Beyond Batch Processing: The Slowdown You Can’t Afford

Traditional batch processing has significant drawbacks when dealing with real-time data. Imagine navigating rush hour traffic with an out-of-date map. While it may provide a rough idea of direction, it does not account for real-time circumstances such as accidents, road closures, or even dynamic pricing on toll roads. By the time you notice these deviations, you’ve lost valuable minutes (or even hours), which has a big influence on your arrival time.

Similarly, typical batch processing views data as a static snapshot. It processes information in huge chunks, usually at regular intervals. This may have been sufficient in a slower-paced past, but in today’s real-time environment, it causes a significant delay. By the time insights are extracted from this stale data, the situation on the ground has most certainly altered.

Consider the example of a financial services firm. Batch processing may detect fraudulent transactions one day after they occur, by which time the harm has already been done. Alternatively, imagine an outlet chain. A batch study of social media sentiment may uncover consumer unhappiness, but by the time they respond, the unfavourable opinion has already been propagated.

This delay is the “slowdown you can’t afford” in today’s competitive business environment. Databricks Streaming provides real-time insights, which are required for real-time choices. It serves as your GPS amid the data deluge, giving the real-time insight required to navigate the market’s ever-changing currents and arrive at your destination – success – ahead of competitors.

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Introduction

Embedded software development has become the precursor to digitalization and digital transformation in a range of applications and industrial sectors. That’s because, with the rapid increase of connected IoT devices, embedded software is powering more interconnectivity and functionality across functions and domains.

Thanks to the wider adoption of AI and machine learning technologies, the embedded software market size is set to cross $40 billion in 2032 – up from $15 billion in 2022. What’s driving this adoption? Embedded software effectively makes common devices and systems “smarter” and “intelligent.” For instance, smart cities leverage embedded software to build an efficient interconnected traffic system. Similarly, digital factories rely on embedded software across machines and devices to drive powerful predictive and proactive maintenance strategies. Additionally, embedded software development is adding power to and complementing technology-led innovations like digital twins and the Internet of Things (IoT).

Let’s take a deeper look at what’s new in embedded software development in the GCC landscape.

Emerging Trends in Embedded Software for Indian GCCs

Here are some of the industry-specific trends that we are likely to see in embedded software development in India-based GCCs:

1 . Automotive industry

According to this PwC report, the automotive industry is set for technology-powered transformation in the years ahead. Even India-based GCCs in the automotive industry are looking to leverage this opportunity to transition and build centers of excellence (COEs) in:

• Embedded systems
• Cybersecurity
• Vehicle designs

Automotive GCCs in India are contributing a revenue of over $3 billion in 2023 – and have an estimated workforce of around 1,10,000. Right from engine regulation to on-time airbag deployment, embedded software in vehicles is enabling important functions.

For example, using embedded systems, auto component manufacturers can develop sensory systems to:

• Detect any low-speed impacts.
• Check real-time road conditions.
• Identify the driver’s voice.

Thanks to its large talent pool, India-based GCCs can also leverage technologies like digital twins, augmented reality, cloud computing, and 5G connectivity.

2 . Healthcare

In the healthcare industry, embedded systems are critical for the advancement of medical devices. Healthcare-specific GCCs in India are accessing the latest technologies in the form of innovation hubs, startup incubators, and hackathons.

Embedded software is powering medical devices such as:

• Heart pacemakers
• Imaging systems for examining the human anatomy
• Surgical robots to extend the capability of human surgeons

Global pharmaceutical companies like Pfizer and Novartis are leveraging their Indian GCCs to

• Perform R&D on new products and clinical trials.
• Develop technology-led solutions in the form of smart wearables, healthcare applications, and electronic health records (EHRs).
• Collect and analyze real-time patient data to extract relevant insights and improve treatment.
  

3 . Manufacturing

A 2021 Deloitte report on GCCs highlights how they are scaling up innovations in the manufacturing domain. Industrial embedded systems in manufacturing facilities can facilitate equipment monitoring and control. For instance, embedded sensors can track machine temperature and pressure levels to detect any internal problems.

Embedded software is also powering “intelligent” robots in manufacturing facilities to assemble products efficiently and on time.

The PwC report also rates India as a cost-effective option for GCCs in the manufacturing domain. 20% of India-based GCCs are serving as advanced innovation partners in manufacturing areas like:

• Digital manufacturing
• Robotic process automation
• Vehicle battery management

4 . Utilities

Embedded software can save utilities over $1 billion each year, while the benefits for each customer utility system amount to $176 yearly. In smart homes, consumers can take control of their energy consumption to support long-term sustainability. For smart homes, embedded software can provide the intelligence for innovations like:

• Smart thermostats
• Smart home automation in the form of voice-controlled devices
• Single centralized control for home lighting, cooling, entertainment, and security.

Similarly, in the domain of smart cities, smart grids can optimize energy consumption, while monitoring systems can track pollution levels and weather conditions in real time. Embedded applications can improve both urban management and the quality of life for city dwellers.

With the growing demand for smart utilities, Indian GCCs can help advance digital technologies to transform this industry. Some of the innovations can include:

• Decentralized energy production
• Real-time data analytics from utilities
• Energy saving

5 . Technology

With embedded software development, technology companies can transform their business ideas and generate revenues. In a competitive environment, technology startups can improve the quality of their applications and development approach. The embedded approach can drive innovation in both the following components:

• Hardware: for example, central processing units (CPUs), power supply circuits, memory devices, semiconductors, and communication ports.
• Software: for example, AI-powered algorithms, cybersecurity, firmware, middleware, and software applications.

Thanks to its focus on digital innovation and the presence of skilled technology workers, India’s GCC sector can play a transformative role in the global technology landscape. Besides Tier-1 cities like Mumbai and Bangalore, GCCs in Tier-2 cities like Pune and Ahmedabad are also driving the next wave of innovation in the technology sector

How Pratiti Technologies can empower embedded software development

Be it for the manufacturing or utilities industry, Pratiti Technologies has established itself as a reliable technology partner for embedded software development services. Our development team brings you the benefit of its expertise in:

• Firmware and middleware development
• Application development

Our customized solutions in embedded software cut across various industries including:

• Healthcare
• Smart Manufacturing
• Automotive
• Energy and utilities

Are you looking for the latest innovations in the domain of embedded software development? Our team is ready to provide the same. Contact us today!

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Introduction

Technological innovations ushered in the age of Industry 4.0 and changed how digital products are conceived, manufactured, and delivered. Smart manufacturing, a key subset of Industry 4.0, is centered on elevating the manufacturing process.

Smart Manufacturing uses cutting-edge cyber-physical technologies, big data analytics, and automation to transform factories into intelligent and adaptive ecosystems driven by data and powered by interconnected machines.

Powerful IIoT platforms like ThingWorx are at the heart of such a transformation as they integrate machines, data, and people seamlessly.

The Complexity of Smart Manufacturing

Smart manufacturing helps create a harmonious ecosystem that anticipates maintenance needs, optimizes production lines, and flags potential issues before they snowball into costly downtime.

It also becomes a key enabler of lean manufacturing by ensuring easy tracking and traceability of the 5M’s – Man, Machine, Material, Method, and Measurement. Forming these connections become foundational to identify issues within complex processes faster and investigate problems and resolve them with utmost agility and velocity.  This can be achieved with ThingWorx.

ThingWorx integrates the physical world of machines and sensors into the digital world seamlessly to collect data and transform it into real-time, actionable insights. It helps manufacturing organizations create the ecosystem to support these principles and seamlessly improve efficiency, productivity, flexibility, and product quality in manufacturing.

ThingWorx empowers manufacturers to achieve Smart Manufacturing excellence by:

Driving Universal Connectivity

Without smart connectivity, there can be no smart manufacturing.

Breaking down communication silos needs a platform like ThingWorx that connects the disparate devices, sensors, and machines seamlessly, irrespective of manufacturers or protocols. This means that all factory assets including legacy equipment can be connected to cutting-edge sensors to make sure that data flows easily.

In essence, ThingWorx allows manufacturers to tightly integrate physical operations with the digital world. That helps manufacturers navigate the many challenges associated with connecting machines, sensors, and data ecosystems. A variety of equipment formats, unstructured or semi-structured data, high data volumes, and speed, are just some of the data issues to cover for seamless industrial connectivity.

With ThingWorx, manufacturers can bring together devices, processes, and systems, to boost performance and visibility across operations. The platform helps manufacturers leverage rich stores of data stored across the 5 M’s to innovate new offerings, create connected business models, and generate recurring revenue streams.

The ThingWorx platform effectively breaks down barriers to data communication. It delivers a harmonious and secure ecosystem where data from these machines, sensors, enterprise systems, etc. can be translated into a useful context and delivered in a cohesive format.

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Introduction

Does the emergence of global capability centers (GCCs) undermine the future of technology-based service providers in India? Technology company CEOs sometimes raise concerns about future business growth when “our customers are setting up their shop in India.”

A common perception is that GCCs and technology partners (TPs) are in somewhat mutually exclusive spaces. Effectively, this means that GCCs are self-sufficient and do not need technology partners!

This is simply a myth.

The truth is that most GCCs require TPs for the following inherent constraints:
● Limited workforce that restricts technology-led innovation
● Limited skills in implementing the latest technologies like digital twins, AR/VR, RPA, etc.
● Faster scale-up, implementation, and turnaround from TPs

The 2024 Davos summit highlighted the importance of business collaboration between GCCs and technology service providers. As partners, both these entities deliver their unique strengths to the mix.

Here are 6 possible business scenarios and drivers where GCCs can engage meaningfully with technology partners:

Technology innovation

With their R&D capabilities, GCCs in India have emerged as the driving force for technology-led innovation for their parent companies. According to the latest estimates, 50% of new R&D centers around the globe qualify as GCCs. This highlights their contribution to the development of new technologies such as AI and digital twins.

As more GCCs grow into innovation-led and data-driven entities, they need the capability to quickly scale up their technology expertise. This is where well-established technology providers can deliver value through:
● Cost-effective support for innovation centers
● Targeted execution of next-gen technology solutions
● Implementation of new solutions and technologies in quick time

Operational growth

Mid-sized GCCs in India typically suffer from stagnation due to their limited size and constrained capabilities. These GCCs generally belong to medium-sized companies with limited ability to compete with the big brands for resources and talent.

Due to a lack of operational growth, mid-sized GCCs struggle to rise to be a truly “innovation” center (or CoE) – or move up the technology maturity level. An additional challenge for them is to tap into India’s pool of technology workers and reduce their skills gap.

By partnering with an established TP, GCCs can address each of these challenges and drive the next phase of operational growth. Through their holistic approach to tech-led innovation, TPs can fulfill the lack of skills and manpower needed by fast-growing GCCs in India.

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Thanks to their use of virtual models, digital twins are sometimes regarded as the same as simulations. Of course, this is not the reality. Despite some similarities in purpose and use cases, digital twins are far more advanced than most simulation tools.

Digital twins enable companies to preemptively check the real-time performance of their finished product. For instance, a “physical” solar panel (fitted with sensors) can produce and transmit data to the digital twin (or model), which can then:

• Run data-driven simulations.
• Measure the performance and health of the solar panel.
• Identify areas of improvement to be applied to the physical product.

Unlike simulations, digital twins can effectively drive business strategy to:

• Improve operational efficiency.
• Automate human or manual tasks.
• Improve data analysis and training.

On the other hand, product companies can run simulations to test their product features – without having to create a “physical” prototype. This is more useful for product designers and engineers, who can create 2D (or 3D) computer-aided models of the product (or process).

5 real-world applications of digital twins

To understand the difference between digital twins and simulations, let’s explore some real-world applications:

1. Discrete manufacturing
Digital twins are richly suited for discrete manufacturers like automotive companies. Automotive companies manufacture vehicles by assembling each part to make the finished product.

For discrete manufacturing, digital twins are more flexible for testing each product part separately across various settings. In short, a digital twin can evaluate the product across its entire lifecycle.

Here’s a case study of how an India-based discrete manufacturer leveraged digital twin technology to improve their machine utilization and planning.

2. Solar-powered renewable energy
In the renewable energy sector, digital twins can leverage real-time data from sensors installed on solar panels and other equipment. For instance, digital twins can utilize solar panel data – including its temperature and energy output – to measure its performance and identify areas of improvement.
Here are some use cases of digital twins in the renewable energy industry:
● Storage and distribution of energy
● Analyzing energy consumption
● Optimizing the design of renewable energy sources

Here’s a recent case study of how a patented digital twin solution for energy analytics improved the performance of a solar power plant by 5-7%.
3. Product designing
Traditionally, computer-aided simulations have provided their value in product designs. However, digital twins are capable of much more. For example, when integrated with an IoT platform, digital twins can process real-time product data faster. This allows product designers to virtually “see” their product’s performance.

Among other benefits, digital twins can analyze the product design through its entire lifecycle and different environments. This enables product designers to improve the product design and make them more resilient. Besides, digital twins can also “simulate” the entire product manufacturing process – much better than “traditional” simulations.

Here’s a real-life case study of how semiconductor company Altum RF reduced its product designing process by 30% with digital twins.

4. Autonomous vehicles
Autonomous (or self-driving) vehicles need real-time data for their predictive abilities. For maintenance purposes, autonomous vehicles can provide garage operators with real-time data about:
● The current performance levels of the vehicle
● Previous servicing records
● Replaced or repaired parts
● Current potential problems in the vehicle

Along with IoT technology, digital twins can capture and analyze autonomous vehicle data, thus saving both maintenance time and effort. They can also provide predictive analytics on the maintenance issues likely to affect the vehicle.

An example is that of Tesla creating a digital twin for every autonomous vehicle that it sells. Connected sensors from thousands of Tesla cars stream real-time vehicle data into its digital twin model, thus helping in determining its current performance levels.

5. Patient care
In the healthcare domain, medical professionals are constantly looking to improve patient treatment, while keeping it safe at the same time. Digital twin solutions in healthcare are the best way of improving patient outcomes. For instance, doctors can now “simulate” the best form of patient treatment – before “physically” making the care.

Here’s how U.S.-based Cleveland Clinic is leveraging digital twins to understand how a patient’s neighborhood can influence their health.

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Introduction

We are in the age of digital technology-led business transformation. And the manufacturing industry is far from being left behind in the race. Over 90% of manufacturing companies are prioritizing digital transformation of their operations. Nearly 75% of business executives expect to realize benefits from this initiative over the next 2 years.

As an Industrial IoT (IIoT) platform, ThingWorx is built to empower the digital transformation of various industries including manufacturing. This platform does not simply enable digital connectivity. It can enable business flexibility and application development at a faster pace to help manufacturing companies extract the maximum advantage out of their IoT strategies.

In this blog, we will look at how 6 global manufacturing companies leveraged ThingWorx to gain a competitive edge.

Case Study#2 – Howden

Based in Glasgow, Howden is a global engineering company manufacturing industrial products for its customers across industries like oil & gas, power, and mining. For over 160 years, this company has focused on air & gas handling solutions and on manufacturing rotating equipment for various engineering projects.

To improve its workforce productivity, the company implemented augmented reality (AR) technology to deliver knowledge and training to its workforce. Through its AR solution, the company improved product demonstration and training by integrating IoT data from ThingWorx.

Here’s how the company benefited from ThingWorx:

• Technical expertise for its internal teams
• Improved workforce productivity
• Eliminated extensive travel for training purposes
• Workforce safety and environmental sustainability

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Introduction

The cost of inefficiency is staggering. A report by Senseye, an AI-powered company, revealed that large industrial facilities lose an average of 323 production hours a year due to unplanned machine failures. This translates to lost revenue, penalties, and wasted resources, amounting to a whopping $172 million per plant annually. Across Fortune Global 500 manufacturing giants, unplanned downtime is estimated to cost a staggering $864 billion, equivalent to 8% of their annual revenue.

Enter Industry 4.0, a revolution fueled by the power of the Internet of Things (IoT), Artificial Intelligence (AI), and Big Data. Imagine real-time production data at your fingertips, predictive maintenance eliminating costly downtime, and a clear path towards sustainability. Industry 4.0 holds the key, but navigating its vast potential can be daunting.

That’s where Pratiti steps in. We’re champions of Industry 4.0, dedicated to empowering manufacturers with the tools they need to not just survive, but thrive. Here, we unveil a game-changer: our 4 new accelerators. These accelerators focus on specific pain points. Let’s dive into the challenges you face and how our accelerators can unlock a new era of manufacturing excellence.

The 4 Game-Changing Accelerators

1. Real-time Production Monitoring Accelerator

Imagine a scenario where blind spots in your production vanish. No more wasted resources, unnecessary delays, or quality control headaches. Pratiti’s Real-time Production Monitoring Accelerator unlocks this reality, transforming your factory floor into a data-driven powerhouse.

Here’s how it tackles common manufacturing woes, using the example of a hypothetical athletic footwear manufacturer.

1. Limited Visibility: Traditionally, ensuring consistent sole thickness across production lines relies on manual checks. This accelerator seamlessly integrates with molding machines, capturing real-time pressure and temperature data. Think of it as a digital twin – a virtual replica mirroring the physical line, allowing for continuous monitoring and immediate identification of inconsistencies.
2. Reactive Maintenance:  Unexpected breakdowns are a thing of the past. The accelerator empowers proactive maintenance by analysing data to predict potential equipment failures before they occur. Imagine a critical machine halting production for an entire shift – a scenario avoided by timely intervention.
3. Inefficiencies and Quality Issues:  Imagine running a bottling line for hours, unknowingly overfilling or underfilling containers. The accelerator provides real-time insights into key metrics like rejection rates and rework instances. This empowers you to identify bottlenecks, optimise resource allocation, and eliminate process variations that lead to inconsistencies.

The Benefits: With this newfound visibility, you can expect:

1. Reduced Rejections & Reworks by Up to 30%
2. Improved First-Pass Quality
3. Increased Asset Utilization by 15-20%
4. Reduced Downtime and Overall Operating Costs
5. Enhanced Process Control and Production Scheduling

2. Condition-based & Predictive Maintenance Accelerator

Unplanned downtime can cripple a manufacturer. Lost production, wasted labour, and scrambled schedules translate into millions in lost revenue. Traditional, calendar-based maintenance often misses the mark, leading to unnecessary maintenance or missed opportunities to prevent breakdowns.

Pratiti’s Condition-Based & Predictive Maintenance Accelerator offers a smarter solution, using the power of data and advanced analytics to transform your operations and maintenance strategy. Let’s see how it benefits our athletic footwear manufacturer:

1. Advanced Condition Monitoring: Imagine embedding sensors throughout the molding machines, constantly monitoring vibration, temperature, and other critical parameters. This accelerator facilitates the implementation of such advanced condition monitoring, leveraging machine learning algorithms to analyse sensor data and detect early signs of potential issues or even failures. Think of it as giving your machines a voice, whispering warnings before problems escalate.
2. Real-time Visibility and Alerts:  Imagine a centralised dashboard displaying the health of every machine on the production line, in real-time, accessible from anywhere. This is the power of the accelerator’s visibility features. Operators can monitor key asset health metrics like Mean Time To Repair (MTTR) and Mean Time Between Failures (MTBF), allowing for prompt intervention and preventive actions to minimise downtime. It’s like having a team of expert mechanics constantly monitoring your machines, ready to address issues before they become major problems.
3. Predictive Maintenance Analytics:  This modulegoes beyond simple monitoring. It utilises advanced analytical models to predict future equipment failures. Imagine pinpointing the exact moment a specific machine component is likely to fail, weeks or even months in advance. This allows for proactive maintenance, replacing parts before they break down, and preventing costly unplanned outages. It’s like having a crystal ball for your production line, ensuring critical equipment is always available when you need it most.
4. Optimised Asset Performance: The result? Optimised asset performance and operational efficiency. Downtime is minimised, production is maximised, and critical machines are always available. This translates to a significant competitive edge in the Industry 4.0 landscape. Imagine a production line running smoothly, consistently producing high-quality footwear, all thanks to the power of predictive maintenance.

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Introduction

In the 1950s, sci-fi legend Ray Bradbury envisioned automated houses by 2026. We’re happy to report that the future is already here! Smart buildings, brimming with sensors and automation, are revolutionising how we live and work. Imagine a building that anticipates your needs before you arrive. These marvels use data to optimise energy, security, and comfort. However, managing this intricate ecosystem is a challenge. Enter the digital twin: a virtual replica that mirrors the physical building in real-time. Think of it as a digital brain, constantly analysing data, predicting problems, and allowing for simulations – all visualised in stunning 3D thanks to game engines like Unity. This article explores the power of Unity in crafting digital twins, transforming smart buildings from data-driven to future-proofed wonders.

Applications of a Digital Twin with Unity

1. Smart Buildings  with Unity:

The concept of digital twins is no longer science fiction, and Unity is playing a key role in its adoption within the smart building industry. Imagine a digital replica of your entire building, a virtual environment powered by Unity’s 3D development platform. Here, you can optimise everything from energy use to space utilisation, revolutionising how we manage and operate smart spaces.

Unity: Building on a Digital Foundation:

1. Leveraging Existing Data: The industry has transitioned from paper blueprints to detailed CAD drawings and models. Unity seamlessly integrates with this existing digital foundation, providing a robust base for your smart building’s digital twin.
2. Connecting the Dots: Most modern building systems, from HVAC to security, now have embedded connectivity. Unity acts as a central hub, connecting these disparate systems and their data streams to create a unified view of your building’s performance.
3. The Power of Visualisation: Unity’s real-time 3D visualization capabilities bring your building’s digital twin to life. Imagine technicians using AR overlays powered by Unity to access maintenance manuals or training guides for specific equipment, streamlining workflows and ensuring meticulous equipment maintenance.
4. Predictive Maintenance for Peak Performance: Integrate sensor data with your digital twin to enable predictive maintenance. Monitor equipment performance in real-time with Unity’s visualization tools, identify early signs of potential problems, and schedule maintenance proactively. This minimises downtime and ensures your building operates at peak performance.

2. Energy Management with Unity:

Energy companies are swimming in data, with sensors, AI-powered cameras, and more constantly feeding information about production, infrastructure, and the environment.  Unity acts as a digital lifebuoy, allowing you to visualise this data in real-time 3D for actionable insights.  Let’s dive into how Unity optimises energy management:

1. Simulating Efficiency:  Before making physical changes to your facilities, test various energy-saving strategies within the digital twin. Model adjustments to lighting systems, HVAC settings, or even building insulation.  Unity allows you to see the predicted impact on energy consumption, helping you identify the most effective and cost-saving solutions.
2. Real-time Monitoring:  Gain a bird’s-eye view of your energy consumption across your entire operation.  The digital twin provides a real-time picture of energy consumption at individual facilities, allowing you to pinpoint areas of high usage.  This empowers you to make proactive adjustments, optimise building efficiency, and minimise wasted energy.
3. Predictive Maintenance for Peak Performance:  Preventative maintenance is key to a smooth-running energy operation.  Integrate sensor data with your digital twin to enable predictive maintenance.  Monitor equipment performance, anticipate potential failures in key components like wind turbines or solar panels, and schedule maintenance before breakdowns occur.  This minimises downtime, ensures peak efficiency, and extends the lifespan of your energy assets.

Benefits of a Digital Twin with Unity

Imagine your office – a hub of activity, but also a place with complex energy needs and ever-changing occupant demands. A digital twin built with Unity can transform your operations by offering:

1. Enhanced Building Management:

1. 1. Centralized Control Panel: View real-time data on energy consumption across different departments or floors. Identify areas of high usage and optimise power allocation for conference rooms or common areas when not in use.
   2. Virtual Simulations: Simulate the impact of installing energy-efficient lighting fixtures or upgrading HVAC systems. See the projected savings on energy bills and environmental impact before making real-world investments.
   3. Comfort Optimization: Track temperature and CO2 levels across different zones in the office. Use the digital twin to predict fluctuations and adjust ventilation systems proactively, ensuring occupant comfort and productivity.

2. Improved Operational Efficiency:

1. Proactive Maintenance: Analyze sensor data from equipment like printers or air conditioners to predict potential failures before they occur. Schedule maintenance within the digital twin to minimise downtime and ensure smooth operation.
2. Virtual Training Ground: Train new hires or existing staff on office procedures like operating complex machinery or navigating emergency evacuation routes within the safe, controlled environment of the digital twin.
3. Reduced Downtime: Test and troubleshoot issues like network connectivity problems or malfunctioning lighting systems within the digital twin first. This minimises disruption to employees and ensures repairs are completed efficiently in the physical office.

3. Data-driven Decision Making:

1. Space Optimization: Analyze occupancy data to understand how office space is used throughout the day or week. Use this information to optimise desk arrangements, identify underutilised areas, and potentially free up space for additional employees or collaborative work zones.
2. Employee Well-being Insights: Monitor factors like temperature, noise levels, and lighting conditions within the office. Use data from the digital twin to understand how these elements impact employee well-being and make data-driven decisions to create a more comfortable and productive work environment.
3. Future-proofing Your Office: By analysing long-term data trends from the digital twin, you can make informed decisions about future renovations, furniture upgrades, and even potential relocation needs based on projected growth and employee preferences.

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Introduction

The ongoing development of smart technologies like IoT is driving forward ambitions of building meaningful environmental sustainability. Along with reducing the carbon footprint, IoT-enabled “smart” buildings aim to optimize resource and energy consumption and reduce operational expenses to achieve these goals.

Globally, the smart building industry will grow from $117.42 billion in 2023 to $568.02 billion by 2032. Today, a smart building is a combination of multiple controls including energy-efficient “smart” ventilation, heating, lighting, and additional systems. As an industry-recognized IoT platform, ThingWorx is designed to enable this wave of smarter buildings.

How does this technology work in smart buildings? Let’s discuss that.

Maintaining Smart Buildings using ThingWorx

Here are 9 focus areas in smart buildings where the ThingWorx IoT platform is making an impact:

1. Energy consumption

The ThingWorx platform enables energy efficiency in smart buildings through continuous monitoring. For instance, facility managers can track floor occupancy and energy consumption using real-time energy heat maps.

Here are some of the common energy-related metrics and KPIs:

• Number and duration of power cuts
• Production costs based on the energy source
• Energy distribution to predict future demand
• Energy availability or uptime

2. Lighting

By sensing room occupancy, ThingWorx IoT can automatically power on (or off) lighting in smart buildings. Using its daylight harvesting feature, companies can design smart buildings to minimize the use of artificial lighting and optimize natural lighting. With ThingWorx’s lighting control systems, they can adjust smart lights to maintain the correct level of room illumination.

Here are some of the common lighting-related metrics and KPIs:

• Area-based light consumption
• Occupant-based light consumption
• Energy consumption for every unit of light output
• Lighting power density
• Light quality and density

3. Fire detection

Through 24/7 building monitoring, the ThingWorx platform enables early detection of building fire incidents along with a quicker response. This functionality enables smart buildings to reduce follow-up expenses and building insurance premiums. With IoT-enabled predictive maintenance, facility managers can anticipate and prevent major damages.

Here are some of the common fire-related metrics and KPIs:

• Frequency of fire incidents
• Average response time to fire incidents
• Completion rate of fire safety training for employees
• Inspection rate of fire safety equipment

4. Building health and management

ThingWorx’s IoT capabilities can also help facility managers monitor building conditions and take corrective actions. For example, using IoT-enabled sensors, they can detect any building damages in the form of surface cracks, water leakages, and gas leaks. For both residential and commercial buildings, ThingWorx can optimize car parking facilities to enhance efficiency and utilization.

Here are some of the common building-related metrics and KPIs:

• Real-time usage of utilities including water, gas, and electricity
• Operational metrics including indoor space usage
• Building safety metrics including fire and emergency systems
• Employee comfort and productivity

5. Electric and hybrid vehicle charging

With the IoT-enabled ThingWorx platform, smart buildings can facilitate the seamless charging of hybrid and electric vehicles (PHEV). Besides the user experience, this feature improves operational efficiency and lowers energy consumption.

Here are some of the common PHEV-related metrics and KPIs:

• Availability of EV charging stations
• Planned maintenance of charging stations
• Service level agreements (SLAs) with third-party maintenance contractors of charging stations

6. Water management

Enabled by the ThingWorx platform, smart water meters can monitor water consumption in offices and building facilities. Instead of manual meters, these sensor-fitted meters can automate real-time collection of water supply and consumption. It can also detect and report any inefficiencies in water consumption patterns. Besides smart water meters, IoT solutions like ThingWorx can “sense” water use and flow.

Here are some of the common water-related metrics and KPIs:

• Remote sensing of water facilities
• Water quality
• Water temperature

7. HVAC management

Through IoT-enabled HVAC management, ThingWorx enables facility managers to monitor the heating, ventilation, and air-conditioning in their smart building. This helps them improvise and reduce energy consumption. With IoT sensors, facility teams can collect and analyze real-time HVAC data for improved comfort within the building.

Here are some of the common HVAC-related metrics and KPIs:

• Asset information based on the type
• Service tests required for each type of HVAC asset
• Maintenance time and costs for each HVAC asset
• Air quality within facilities
• HVAC defects and problems

8. Elevators

The ThingWorx IoT platform also makes “traditional” elevators smart by reporting their real-time performance and maintenance data. Using this platform, elevator engineers and maintenance teams can:

• Reduce their downtime.
• Improve their efficiency.
• Detect any emergencies.

Overall, this helps them reduce elevator repair time and improve the first-time fix rate.

Here are some of the common elevator-related metrics and KPIs:

• Tracking of elevator usage and patterns
• Maintenance-related metrics
• Remote monitoring

9. Building access and security

By deploying the ThingWorx platform, facility managers can deploy a secure access control mechanism for smart buildings. This IoT platform works seamlessly with a host of security devices including access cards, surveillance cameras, and perimeter-based access (for authorized personnel).

Implementing Predictive maintenance for Smart buildings using Databricks

For smart buildings, predictive maintenance is all about how to maintain the assets (as listed in the previous section). Depending on each asset’s real-time age and condition, facility managers can work out their productivity and availability. This enables them to schedule maintenance operations at the right time, thus reducing expensive asset downtime.

Using IoT data from ThingWorx, the Databricks tool can leverage its predictive analytics capability to predict and prevent the next breakdown. With its Data+AI technology, Databricks can address industry challenges such as:

• Monitoring real-time asset performance.
• Forecasting energy consumption using machine learning.
• Using advanced analytics to improve smart building analytics and supply-demand balance.

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