Solution Overview

Cognizant OnePlant™
How to pivot your silo-based manufacturing operations toa more integrated framework capable of dealing with new
requirements for mass customization.

March 2019

Solution Overview

Are your manufacturing operations ready formass customization?
Industry 4.0 is going to revolutionize manufacturing. Are you ready to
go digital and transform your enterprise?
The world of manufacturing has been transformed by the fourthindustrial revolution.
Industry 4.0 provides a blueprint that manufacturing operations can follow for digital transformation that
focuses on advanced technologies and architectures including cyber-physical systems, robotics and AI.
The challenge for traditional manufacturers is how to retrofit these ‘Industry 4.0’ operations strategies andbusiness processes to organizational structures based on silos, with little integration between operational
technology, IT, and business units.
New entrants are meeting growing requirements for mass customization, and reducing capital andoperational expenditure, by leveraging technology trends such as 3D printing, sensors, robotics, machinelearning, and artificial intelligence.
Product feature, function, availability and support is being driven by an on-line retail mentality wherecustomers:❙❙ Want the product now❙❙ Want it built to their exact requirements❙❙ Insist it’s available at wholesale prices❙❙ Don’t expect it to break (and if does, expect it to be replaced at no cost)❙❙ Expect it to be intuitive to use❙❙ Easily customizable❙❙ Completely automated

These demands are almost impossible for traditional manufacturing models to satisfy. Operating models
need to be recast, by leveraging new technologies and reimaging business processes to provide a seamlessclient experience across all aspects of the value chain.

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Solution Overview

Traditional manufacturing operations are designed to support mass production of similar products.
This cookie-cutter approach has typically resulted in the creation of deep silos dedicated to a single
aspect of production. The manufacturing systems these silos are dependent on were not designed withinteroperability in mind, limiting the flow and integration of data.
The results, all too often, are:❙❙ Unexpected downtime of equipment and machinery❙❙ Increasing operational costs❙❙ Unanticipated product line issues and the inability to quickly implement change orders❙❙ Little capacity to control or eliminate product and process defects❙❙ Problems in collating data for decision making❙❙ Poor visibility of operations on the factory floor

Fixing these challenges calls for a holistic approach from Cognizant.

Intelligent manufacturing
Traditional IT

IT-OT
Convergence

Machine Learning
and Analytics

Traditional
Machines

M2M
Communications

Emerging BusinessModels

Traditional
Operating

OptimizedOperations

Limited Visibilityof KPIs

Computerization

Connectivity

INDUSTRY 3.0

Enterprise Wide
KPIs

Visibility(Seeing)

Transparency(Cognize)

Predictability(Equipped)

Adaptability(Optimizing)

INDUSTRY 4.0 / Intelligent Manufacturing

Figure 1

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Solution Overview

Lead the revolution
Traditional manufacturing operations cannot be transformed
overnight, nor should they be. You should consider a structured
approach to transformation, which allows you to gradually integrate
aspects of your business that will result in more agile and productive
operations.
Cognizant OnePlant™ is a framework that enables manufacturers to achieve unified operations by aligningand integrating: operational technologies on the factory floor with IT systems, supporting businessprocesses and organizational models.
Our team of smart manufacturing experts will work with you to:❙❙ Define a transformation roadmap❙❙ Select systems and products❙❙ Implement the solution❙❙ Enable user adoption and change management❙❙ Provide total care during deployment as well as ongoing production support

OnePlant can be tailored to your existing operations and fit into your businesses current phase on its smart
manufacturing journey, including enterprise resource planning and manufacturing execution system
rollout, integration, and access.
Implementation of the framework enables the integration of supply chains with products and services,
creating a cyber-physical system with information, not data silos, to support predictive, agile operations
and informed decision making. All this will help lower operational expenditure and provide insight to capital
expenses and risk based on actual, consolidated factory floor data, delivered in real time, integrated andanalyzed within operational support and engineering systems.

Reduce operating costs
Technological integration that improves efficiencies and reduces operational disruptions will reduce youroperating costs. What is more, with continuous improvement in processes and management, reductions
will occur year on year.

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Solution Overview

Improve asset productivity
Thanks to self-monitoring and predictive maintenance through machine learning, automation, and artificial
intelligence, your staff and your machinery will become more productive.

Increase staff motivation
Moving to Industry 4.0 with our help will have benefits for your entire staff. Improved skillsets, better
employment opportunities, greater employee satisfaction, and higher staff retention will be some of theeffects for employees working in a new technology paradigm.

Get greater flexibility
Cognizant OnePlant™ will provide improved ability to address fluctuating customer demands, identify andexploit market opportunities, and develop new products and services, all based on expanded information
networks. This increased agility and flexibility will give your business a true competitive edge.

Boost margins and value
Customization and demand-driven product strategies will allow your business to give customers what
they want at a lower production price. That added value allows you to charge more than for standardized
products, ensuring higher margins.

Make gains quickerCognizant OnePlant™ gives manufacturing operations access to a new weapon: information. This
information can be used to launch new service or product lines and create partner ecosystems using a
different, non-traditional, and potentially lower capital expense model.

The difference is delivery
When deciding to transform your business, you not only need outside
expert help but also the confidence that it can be trusted. Cognizant
is uniquely placed to be your transformation partner. We are an
experienced global systems integrator with a specific knowledge of themanufacturing space.
Our in-house resources, including our knowledge base, are unmatched. Our team has a proven trackrecord of successful deployment, utilizing the tried-and-trusted OnePlant framework, and PACE
methodology. Where others promise you Industry 4.0, we deliver.

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Solution Overview

Cognizant smart manufacturing in action
Client challenge
A pharma major with 15 manufacturing sites across the globe and a diverse IT landscape wanted to shift its
business strategy by moving from large-volume products to a higher number of low-volume products. Its
goals were to:❙❙ Reduce new product introduction cycle time❙❙ Focus on business and operational excellence to drive margins❙❙ Move towards modular and disposable technologies for manufacturing❙❙ Pioneer newer technology in packaging and devices

Our solution
Cognizant developed a four-year roadmap for manufacturing IT that improved business efficiencies forthe client and helped the shop floor to move towards a proactive and predictive control model. The
process involved:❙❙ Assessing the state of manufacturing processes and systems, establishing the maturity of key functions❙❙ Benchmarking the maturity of business functions with other pharma organizations❙❙ Analyzing best practices and future needs to identify gaps and improvement opportunities❙❙ Performing a cost-benefit analysis to quantify potential benefits❙❙ Advising on future strategy roadmaps for manufacturing IT

Business outcome
Cognizant developed a four-year roadmap aimed at improving 14 key result areas, providing cost savings of$5 million per year per site in the areas of production, quality, maintenance, inventory, recipe management,
key performance indicator management, and governance. Per-year savings included:❙❙ $1.3 million in scrap and rejects❙❙ $7,500 in paper and printing❙❙ $1.68 million in batch reviews and release times❙❙ $780,000 in recipe authoring time❙❙ $1.08 million in testing and validation❙❙ $210,000 in deviations and non-compliance❙❙ $75,600 in manual data entry time for perfect Index calculations

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Solution Overview

Business advantages in brief
What challenges does yourcompany face?
Through the orchestration and optimization of manual and automatic procedures andprocesses, both inside factories and across the entire value chain, the Cognizant SmartManufacturing Solution will help you:❙❙Lower annual operating costs year on year❙❙

Improve operator and asset productivity❙❙

Enhance employee motivation❙❙Get greater agility and flexibility❙❙

Respond to customer demands❙❙

Boost margins and added value❙❙

Achieve greater monetization

Lets get started
The next industrial revolution is starting right now.
If you would like to know more about how your business can benefit from it, please write tooneplant@cognizant.com or manufacturing@cognizant.com.

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About Cognizant Manufacturing
Cognizant’s Manufacturing and Logistics business unit operates as a trusted partner to global manufacturing leaders, helping them accelerate businessperformance in the digital world. The unit is recognized for its forward-looking approach by industry gurus, such as IDC MarketScape, which bestowed
on it a “Leader” rating for service lifecycle management. Our business consulting professionals ensure that manufacturing and logistics clients receive
exceptional business results from their technology investments and sourcing programs. Our domain solutions leverage digital technologies to buildsmart products, connect with digital consumers, provide real-time visibility into manufacturing operations, and automate knowledge work with cognitivecomputing. Learn more at www.cognizant.com/manufacturing.

About Cognizant
Cognizant (Nasdaq-100: CTSH) is one of the world’s leading professional services companies, transforming clients’ business, operating and technology
models for the digital era. Our unique industry-based, consultative approach helps clients envision, build and run more innovative and efficient businesses. Headquartered in the U.S., Cognizant is ranked 193 on the Fortune 500 and is consistently listed among the most admired companies in the world.
Learn how Cognizant helps clients lead with digital at www.cognizant.com or follow us @Cognizant.

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