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Transforming Manufacturing with Smart Technology

Dive into the Smart Lab case study, where smart technology meets manufacturing, setting new benchmarks in agriculture production with optimized processes, real-time monitoring, and advanced quality control. Learn how this pioneering project is shaping the future of industry manufacturing.

Key Challenges

  • Process Excellence: Syngenta aimed to boost manufacturing efficiency for operational excellence.

  • Smart Integration: Adopting smart manufacturing in varied zones like Formulation Engineering, Packaging, and an Autonomous Supply Ecosystem created thrilling integration chances.

  • Data Analytics: A vital command center to collect, monitor, and analyze process parameters, driving R&D for product enhancement and innovation.

  • Production Management: Embracing the MES concept in the SMART Lab opened doors to connect production, manage orders, and ensure real-time plant-to-center communication efficiently.

  • Inventory Tracking: Tracking inbound and outbound information, inventory status, and cycle counting was a complex task that required an intelligent and automated system.

  • Quality Assurance: Guaranteeing product quality throughout the capping process was crucial to prevent potential final product issues.


  • Optimize Manufacturing Processes

  • Real-time Data Monitoring:

  • Packaging Compatibility Testing

  • Autonomous Supply Ecosystem

  • Enhance Quality Control


1. Process Digitalization:

SMART Lab implemented a state-of-the-art automated production line with seven modules, including Bottle Loading, Filling, Capping, Labelling, Inspection, Case Erector, and Packing Stations. These modules streamlined the manufacturing process, reducing human errors, and ensuring consistency in product quality.


2. Nerve Centre:

A centralized command center was established, integrating SCADA (Supervisory Control and Data Acquisition), WMS (Warehouse Management System), MES (Manufacturing Execution System), BMS (Building Management System), and a Dashboard. The Nerve Centre, hosted on Stratus ftServer, provides a robust and fault-tolerant infrastructure ensuring continuous operations. This fault-tolerant architecture enhances the reliability and availability of the Nerve Centre, contributing to uninterrupted real-time monitoring, data analytics, and performance insights. These benefits not only optimize processes but also provide crucial support for ongoing research and development efforts.


3. MES and Integration with Remote Site:

SMART Lab integrated its manufacturing processes with the Building Management System, overseeing vital facility systems which included:

  • Compressed Air System: Optimize the usage of compressed air, identify potential leaks, and reduce energy wastage.

  • Energy Usage Monitoring System: Real-time monitoring of energy consumption improved energy management and efficiency.

  • Air-Conditioning and Mechanical Ventilation (ACMV) Control & Monitoring System: Enabled seamless control and monitoring of the ACMV system.

  • Waste Collection System: Automate waste disposal processes, enhancing efficiency.

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  • Increased Efficiency: Boosted efficiency by reducing manual work and cutting production times.

  • Real-time Insights: The Nerve Centre enabled real-time monitoring, data analytics, and informed decision-making

  • Enhanced Quality Control: Integrating torque sensing in Capping Station enhanced quality control, reducing defects and customer complaints.

  • Improved Inventory Management: The Autonomous Supply Ecosystem with AS/RS and AMRs streamlined material handling, leading to better inventory tracking, cycle counting, and overall warehouse efficiency.

  • Lower total cost of ownership: Save up to 40% when you factor in acquisition, deployment, management, and unplanned downtime costs.

  • Future Readiness: The Packaging Development Area readied Syngenta for packaging shifts, ensuring swift transitions and quicker product launches.

Mechanical Engineer
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