Client

Our client is a global manufacturing leader for heavy trucks, buses, and engines in industrial and marine applications. With operations in 100+ countries and a network of over 1,800 service points, they are committed to providing sustainable and efficient transportation solutions. As the transition to fossil-free transport accelerates, battery assembly has become a strategic priority. Facing the need for streamlined, data-driven processes to meet sustainability goals, they sought digital solutions to modernize operations and improve production efficiency.

Market Trends in the Battery Industry

The growing demand for lithium-ion batteries, driven by the rise of electric vehicles and renewable energy storage, is reshaping manufacturing. Companies are adopting advanced automation and robotics to boost production efficiency and integrating AI and digital twin solutions for predictive maintenance and real-time monitoring. Internet of Things (IoT) solutions enable seamless data collection and communication, while growing regulatory and sustainability requirements emphasize green practices and traceability. Many manufacturing leaders are seeking digitalization solutions to enable fully digitalized and integrated manufacturing with seamless, scalable and efficient operations in the automotive industry.

Challenges

Inefficiencies in existing processes hindered the client’s ability to scale and meet the increasing demand for high-quality, reliable batteries.

The client’s manufacturing workflows required greater efficiency, traceability, and sustainability to stay aligned with evolving industry standards.

Limited visibility across the battery production lifecycle made it difficult to monitor performance, identify bottlenecks, and ensure consistent quality.

Manual interventions and siloed systems led to frequent errors, rework, and delays in reporting and decision-making.

Disparate data sources and lack of centralized data management created challenges in maintaining data integrity, consistency, and accessibility.

LTIMindtree’s Solution

Our client selected LTIMindtree for our expertise in large-scale factory digitalization. After analyzing their
operations and automation needs, we proposed a comprehensive, integrated solution to enable digitalization of
their
battery manufacturing operations. This enabled seamless communication with their SAP S/4 HANA system,
establishing a
digital thread for smart manufacturing across their operations.

Key steps in the digitalization journey:

* Click on Solution Names to read more

Order management

We transferred production orders from SAP S/4 HANA to the shop floor system for seamless work receipt and real-time processing.

Real-time delivery of sub-components

Integration with AGVs ensured real-time material feeding based on active work orders, improving efficiency and reducing delays.

Order tracking and visibility

Real-time tracking of orders and material consumption, along with digital work instructions, enhanced operator visibility and reduced errors.

Material management

ERP integration provided real-time material tracking and automated replenishment, ensuring timely resource availability.

Logistics management

AGVs efficiently routed finished goods from production to storage upon completion and certification.

Figure 1: Industrial Digital Thread Integration with ERP, MES, and AGV Systems

Tech Stack

SAP S/4 HANA
Enterprise Resource Planning (ERP)
Burst Test Function Automation
Manufacturing Execution System (MES)
Internet of Things (IoT) Platforms
Delmia Apriso MES
Automated Guided Vehicles (AGVs)

Business Benefits

Our digitalization solution streamlined operations for the client leading to several benefits:

Efficient monitoring and control

Digitized battery assembly led to streamlined battery assembly operations across 10+ assembly lines with over 50 user screens enabling efficient monitoring and control.

Seamless integrations

Built 10+ custom interfaces with SAP, ensuring smooth communication with 1000-1200 in-and-out messages per minute.

Real-time data flow with digital thread

By integrating various systems, we established a digital thread for smart manufacturing, enabling seamless, real-time data flow across the plant.

Future-proof new system architecture

Collaborated with the client’s architects to integrate SAP S/4 HANA, creating a new reference architecture for future digitalization efforts.

Sustainability advancements

Contributed significantly to the client’s sustainability goals, as digitization enabled complete monitoring and control of operations leading to reduced waste.

Burst testing automation

Automated the burst test function, reducing manual errors, maintaining traceability in the MES, and ensuring accurate future tracking.

Conclusion

The client partnered with LTIMindtree to modernize their battery assembly process in alignment with their vision of producing sustainable products. This pioneering project has established a digital thread for smart manufacturing and also set a strong foundation for future initiatives. By integrating advanced technologies and creating new system architecture, we have enhanced operational efficiency and traceability while driving sustainability efforts. Our solution for the digitalization of battery manufacturing played a pivotal role in enabling a seamless transition towards more sustainable transport solutions. Thus, digitalization is essential for battery manufacturers to meet rising market demands, sustainability goals, and stay competitive.

Quotes

At LTIMindtree, we’re proud to have accelerated digital transformation for our client by integrating advanced digital technologies across their battery assembly operations. This initiative not only enhanced efficiency and traceability but also laid the foundation for a future-ready supply chain, driving meaningful progress toward their 2030 sustainability goals.

– Srini Rao, Executive Vice President (EVP) and Chief Business Officer, LTIMindtree

Looking for smart battery digitalization and assembly line scaling solutions?

Reach out to us at mfg.communications@ltimindtree.com

Client

Market Trends in the Battery Industry

Challenges

LTIMindtree’s Solution

Tech Stack