Tech Mahindra June 2020

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Tech Mahindra shows global manufacturing the road to digital optimisation IN ASSOCIATION WITH



Powering future factories WRITTEN BY




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Tech Mahindra’s Head of Aerospace and Defence Manufacturing, Debasis Bisoi, on IoT, Blockchain, AI, and the Factory of the Future


obody who knows India can be unaware of Mahindra. The logo appears on the front of buses, trucks, motorcycles, com-

mercial vehicles, SUVs and cars, as well as the ubiquitous three-wheelers (available since 2018 in all-electric format). Mahindra is one of India’s 04

great industrial dynasties, a global brand today, with factories in South Korea, South Africa, the US, Australia and China, and a strong presence in defence and energy. Its Chairman, Anand Mahindra, is the grandson of JC Mahindra, one of three family members who founded Mahindra & Mahindra as a steel trading organisation in 1945. Anand Mahindra is also the founder of Tech Mahindra. An early entrant into the burgeoning though incipient industrial electronics market in 1983, the company was started as a JV with British Telecom, subsequently buying out this partner, growing organically and by acquisition, and today having a presence in all of the world’s principal industrial markets. Tech Mahindra is the highest ranked non-US company in the Forbes Global Digital 100 list, employs more than 131,500


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“ Our Aircraft Health Monitoring System (AHMS) is a solution that uses real-time data captured through integrated sensors throughout an aircraft parts to enhance reliability and safety” 06

— Debasis Bisoi, Vice President Manufacturing Vertical, Digital and IOT Solutions

professionals across 90 countries and includes a number of Fortune 500 companies in its global client list of over 190 companies. As you’d expect from a subsidiary of a group rooted in vehicle making, manufacturing is one of the biggest verticals in Tech Mahindra. The business is focused on the three key trends it has identified as facing manufacturers in the 21st century: the explosion of intelligent devices and increasing human/robot collaboration; leveraging the power of new technologies to meet the growing demand for mass customisation; and tackling the exponential growth of content consumption – that is, the power of data driving rapid IT/OT convergence. Of course, global manufacturers are aware of these trends, but putting them to the service of businesses and customers remains a huge challenge. Tech Mahindra’s four ‘big bets’: factories and SCM, smart products, reliable aftermarket (integrating field warranty with product design and production quality), and mobility and experience, will have the most transformational effects on customers’ businesses

Celebrating Change & ChangeMakers; the Digital ChangeMakers CLICK TO WATCH



07 – and the enterprises that will create

‘factory of the future’, with an emphasis

the future are those willing to bet on

on aerospace, defence and process

technologies that will disrupt industries

manufacturing. “I’m responsible for

and will create new opportunities. The

setting the key directions for these

company collaborates with disruptive

sub-verticals, developing strategic

new age technology players, startups,

plans, identifying focus areas, improv-

and academia globally, drawing them

ing solution offerings, identifying

together with academics and custom-

mid-term course corrections, improv-

ers at its annual TechmNxt.i forum.

ing win ratios and developing teams,”

Leading these initiatives since 2012

he explains. “I also work extensively

from Tech Mahindra’s Bengaluru

on mergers and acquisitions and

HQ is VP, Debasis Bisoi. His passion

engage in providing thought leader-

is developing and delivering digital

ship to our manufacturing clients.” His

manufacturing solutions and strategic

team has co-authored more than 180

initiatives in areas like IoT and the

patents and disclosures for these w w w.te c hma hi nd ra . com



clients, addressing their digital disrup-

leveraging cutting-edge cloud

tion issues and ‘pain points’ with the

computing, sensor, IoT and big data

backing of Mahindra’s many centres of

technologies to perform deep analyt-

excellence and strategic partners.

ics of the aircraft’s health status. The

Bisoi is keen to point out his unit’s

unit collects aircraft operation and

contribution to its high profile custom-

performance data from every system

ers. “A good example is our Aircraft

during flight. Examples include avion-

Health Monitoring System (AHMS).

ics, flight controls, fly-by-wire, landing

This is a solution that uses real-time

gear, braking systems, environmental

data captured through integrated

control systems, thrust reversers,

sensors on aircraft parts to enhance

engines, electrical systems, auxiliary

reliability and safety.” Among many

power units (APUs) and more. On the

clients, the system was adopted by

ground, the AHMS system performs

a Canandian aircraft manufacturer,

the detailed analysis of the transmitted

on-board data to support a wide vari-

to advanced automation via chatbots

ety of operational decisions.

and improved strength deployment

In that case, Tech Mahindra engi-

inventory (SDI) scores, the team

neered a system solution. It is just as

improved first-call resolution (FCR)

effective in the business process field,

from 74% to 91% and introduced auto-

though. For another client, this time a

mation that reduced turnaround time

major Swedish car manufacturer, the

for requests by 75%. Monthly request

problem was centred around global

numbers went down by 3,500.

dealer support and access manage-

In the world of process manufactur-

ment – the company was dealing with

ing, Bisoi continues, his team partnered

40,000 requests and 20,000 calls a

with the largest global chemical manu-

month. By setting this client on the road

facturer in its journey from a monolithic 09


Debasis Bisoi Title: Vice President Manufacturing Vertical, Digital and IOT Solutions As VP in manufacturing vertical Debasis Bisoi heads Tech Mahindra's digital initiatives, solution offerings, verticalisation, top-line growth and key customer relationships in aerospace and process manufacturing industry verticals. He provides leadership to key alliances in the IoT and cognitive space, ventures and strategic initiatives. Bisoi is responsible for Tech Mahindra’s first and largest and multiple subsequent digital relationships in the manufacturing vertical, including solutioning, sales and delivery. He has been instrumental in incubating and growing digital manufacturing, the factory of future, IOT relationships spanning business development, solutioning and delivery. He was an IOT thought leader finalist in the first IOT Congress in 2016 w w w.te c hma hi nd ra . com


In a progressive market changing environment, the manufacturing vertical is fuelling innovation in several industries. Deep expertise and a collaborative approach can successfully manage complex global supply chains, coste�ective manufacturing facilities, and multifaceted product lifecycles, thereby de�ning the industry leaders of the future. Next-level technologies will enable manufacturers to roll out new applications, such as advanced monitoring and diagnostics, machine performance optimization, and proactive maintenance. There are certain partnerships that are industry rede�ning, like the powerhouse collaboration between Tech Mahindra, part of the Mahindra Group, the $15 billion Indian conglomerate and Dell Technologies, who transform IT from edge to core to cloud. Together, we are o�ering leading edge solutions that alter outcomes in the manufacturing industry. To help Aerospace and Defense, Automotive, Durable Goods, Industrial Equipment, and High Tech Manufacturers succeed, Tech Mahindra Services and Dell Technologies provide a unique combination of domain knowledge and technology-based solutions. Our IT and business process solutions are speci�c to each customer's needs and focus on delivering real business results.

The Aircraft Health Management System (AHMS) – Analytics platform It's vital that every aircraft is in peak operational condition, ensuring this takes a monumental amount of technology. The Tech Mahindra - Dell Technologies o�ering comes with Cloud to Ground Solution, Data Extraction, Complex Data Visualization and Data Analytics. This solution had to address a set of diverse challenges. The biggest was that it had to work on a Public Cloud based Analytics Platform with the ability to support the customer's data sovereignty demands. Built on Dell Technologies validated and ready solution architecture, this used Hadoop to gain deeper insights and enhance data-driven decision making, rather than designing a solution from scratch. Flexible and scalable, the solution starts with a small platform, and grows as capacity demand increases. The bene�ts were signi�cant. A 20-25% Improvement in aircraft availability and 17% Improvement in First Time Fix rate.

Hot & Cold Storage. Infra for ADAS Solution. Tech Mahindra and Dell Technologies come together to o�er OEM and Tier-1 enterprises an end-to-end ADAS/Autonomous vehicle consulting, solutions and system integration service. This includes infrastructure (including Hot, Warm & Cold storage), software, applications, annotation services, software & hardware validation, vehicle integration, testing, etc. 8 out of 10 top global auto OEMs incorporate this solution today. ADAS development demands signi�cant solution integration. The challenges are many, when building an e�cient data management infrastructure and software, which can handle incoming semi -structured, unstructured camera and sensor data in the range of petabytes. This joint solution delivers massive scaling, from 10s of TB to 10s of PB. It is also simple to manage, with uncomplicated volume & single �le systems ensuring extreme performance at scale.

Process HistorianData Management solution This solution re�ects Tech Mahindra's decades of experience working with manufacturing companies, integrating its in-depth knowledge of technology platforms, understanding of business needs and worldclass delivery capability, combined with Dell Technologies proven eco-system to o�er end-to-end IT and engineering solutions. This is evident in the modern data center which enables extra data to be stored with a smaller footprint and archival. The ease of management and the modern and scalable platform keeps much of the data online, delivering a far higher level of data management.

Workspace as a Service. WaaS. Rising adoption of BYOD across various industries, ease of deployment, scalability, quick availability, combined with the increasing demand for a�ordable virtual desktop virtualization are all boosting the growth of WaaS, organizations are realizing the bene�ts of WaaS that enables them to become less constrained by geography and reduce infrastructure managing costs, while maintaining their employee experience. Tech Mahindra Dell Technologies WaaS o�ers the best user experience keeping costs low and o�ering extra agility. This solution classi�es the user personas and creates a platform without duplicating the investment made by the customer. It uni�es the remote access system to a common virtual platform using WaaS framework. This joint solution enables your employees to run the latest versions of their productivity applications on any device without any capital costs. It also comes with Dell Secure Works security monitoring.

The Tech Mahindra Dell Technologies alliance is committed to o�ering feature rich solutions that empower greater productivity and e�ciency. Focusing on shared goals, this partnership feeds o� synergies and the result is that a broad spectrum of clients across the manufacturing vertical accelerate innovation.

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“ The Factory of the Future is about positive environmental impact in terms of reduced waste and carbon footprint” — Debasis Bisoi, Vice President Manufacturing Vertical, Digital and IOT Solutions


throughput, higher utilisation, flexible manufacturing lines, reduced timeto-market, and higher visibility across other enterprise applications like MES, SCM, and ERP. It is also about new digital technologies and their smooth alignment with human capital and change management, and achieving the desired target state. He adds: “FoF is about positive environmental impact in terms of reduced waste and carbon footprint. Digital Fabric enables horizontal integration across the product development and value chain, and vertical integration CIO organisation to a product-centric

across manufacturing. It ensures a true,

business, also serving as a key inte-

extended digital enterprise.” As a major

gration partner for acquisitions. “Our

client, the Mahindra Group vehicle

current focus areas in manufacturing

plants also benefit from a partnership

are automation and data exchange

with Tech Mahindra. “We have a very

to facilitate Tech Mahindra’s Factory

active engagement with Mahindra &

of Future (FoF), a smart factory with

Mahindra in its digital transformation

cyber-physical systems, IoT, cloud com-

journey. We identify key solutions areas

puting and cognitive computing as the

on FoF initiatives, and work jointly in

core enablers. Our solution empowers

building proofs-of-concept (PoC’s)

clients to adopt these technologies and

and scaling up.” Tech Mahindra has

overcome the traditional problem of vis-

implemented end-to-end Industry 4.0

ibility across the plant and enterprise.”

solutions at the Chakan factory near

The FoF at its core, he explains, is

Pune, one of India’s largest and most

about automation and robotics, quality

automated car plants, including PoCs, w w w.te c hma hi nd ra . com



SCADAs, historians, simulations and IT tools like the MES, PLM, ERP, integrating them with the shop floor systems. Digital transformation can be a minefield for companies large and small, Bisoi acknowledges in conclusion. “Tech Mahindra has observed that only 30% of pilots end up reaching scale across the entire organisation: that means companies are failing to capture value from 70% of their pilots. We have identified two steps that can help them overcome 14

‘Pilot Purgatory’. The first is our ‘digital foundry model’. We start with the ideation phase, by identifying all use cases

“ A future-proof, scalable, sustainable network architecture is built to handle the data explosion arising from new age digital disruptions” — Debasis Bisoi, Vice President Manufacturing Vertical, Digital and IOT Solutions

that create value and build PoCs and MVP for cases with good RoI. Only then do we build an agile, product aligned solution for them. Next is to upgrade their factory network infrastructure. A future-proof, scalable, sustainable network architecture is built to handle the data explosion arising from new age digital disruptions.” At present, in common with the rest of his team globally as well as everyone in India able to do so, Bisoi is working from home. With leading-edge digital

$4.9bn Revenue in US dollars

131,522 Number of employees

communication systems and develop-

develop, mass produce and distribute

ment tools at their command, the work

low cost personal protection equip-

of IT professionals is less disrupted

ment (PPE), a powerful branded hand

than those with indispensable work

sanitiser, and even a newly designed

among the community. The impact of

respirator, all specifically targeted at

the global pandemic on the group’s

the needs of India’s people. The indig-

manufacturing plants themselves has

enous ventilator, developed in March,

been met with exemplary and char-

sells at less than 7,500 rupees (not

acteristic Indian compassion allied to

even $100), the hand sanitiser at under

the group’s agility and flexible manu-

400 rupees per litre, or around $5.

facturing capacity. Anand Mahindra was quick to repurpose large sections of R&D and production capacity to w w w.te c hma hi nd ra . com