Executive Summary

The client set out to achieve smart-factory (4IR) certification while production commitments kept growing. Reaching the certification bar required automation and process improvements across live manufacturing lines, without disrupting output, and with enough engineering capacity to run the transformation and daily operations in parallel.

Objectives

• Support the client's smart-factory (4IR) certification initiative
• Deploy automation and process improvements on operating lines
• Improve takt time and annual unit throughput on flagship lines
• Scale engineering capacity quickly without sacrificing quality

BEPC's Role

BEPC deployed and managed a 50-engineer team embedded with the client's operations, executing the automation and process-improvement workstreams that supported the smart-factory certification initiative while production continued.

Scope & Approach

• 50 engineers deployed across automation and process workstreams
• Process improvements targeting takt time on flagship lines
• Automation initiatives supporting 4IR certification criteria
• Throughput and capacity-relief improvements on live production

BEPC sequenced improvements line by line so certification workstreams advanced while production kept running, pairing automation deployments with process-level changes that compounded into measurable takt-time and throughput gains.

Outcomes

The program improved takt time by 12%, added more than 40,000 units of yearly throughput, and delivered 4.5M of relief on the client's flagship lines, advancing the smart-factory certification initiative with a 50-engineer BEPC team.

Metricas clave

• Takt time: 12% improvement (Faster line cadence)
• Yearly unit throughput: +40,000 units (Added capacity)
• Flagship-line relief: 4.5M (Capacity freed)

Evidencia visual (descripcion)

• Connected manufacturing analytics supporting the smart-factory certification workstreams.
• Automation and process improvements executed on live production lines.

Trust & References

Fifty BEPC engineers worked inside our operation like they were our own people. Takt time improved 12% on lines that never stopped shipping, and the smart-factory evidence they built moved our certification forward faster than we planned.

Ultima revision: July 2026