Executive Summary
The automotive industry is experiencing transformative changes led by the electric vehicle (EV) revolution. With rising environmental concerns and a global push toward sustainability, EVs are no longer just an alternative—they’re becoming the norm. As demand surges, battery manufacturers face the critical challenge of scaling up production rapidly without compromising safety, quality, or efficiency. Simply expanding factory capacity is no longer enough. Without a cohesive digital ecosystem, meeting the performance, safety, and sustainability standards required for mainstream EV adoption becomes increasingly difficult.
A leading global EV battery manufacturer faced this very challenge in scaling its operations. To accelerate its transformation and build a resilient, future-ready production ecosystem, the company partnered with ITC Infotech to implement an integrated PLM-MES solution.
Business Challenge
- To scale Gen 5 and Gen 6 battery production while ensuring quality, safety, and compliance
- Integration of discrete, batch, and continuous manufacturing under a single solution
- Requirement for harmonized ERP and PLM platforms to support high-speed manufacturing
- Infrastructure was unable to support high-speed, large-scale production
- Dependency on critical raw materials (lithium, nickel, cobalt) requiring stringent traceability
- Variability in manufacturing processes leading to inconsistent yield
- Complex regulatory compliance demanding enhanced data capture and reporting
- Manual processes causing higher error rates and production inefficiencies
Business Challenge
- To scale Gen 5 and Gen 6 battery production while ensuring quality, safety, and compliance
- Integration of discrete, batch, and continuous manufacturing under a single solution
- Requirement for harmonized ERP and PLM platforms to support high-speed manufacturing
- Infrastructure was unable to support high-speed, large-scale production
- Dependency on critical raw materials (lithium, nickel, cobalt) requiring stringent traceability
- Variability in manufacturing processes leading to inconsistent yield
- Complex regulatory compliance demanding enhanced data capture and reporting
- Manual processes causing higher error rates and production inefficiencies
Our Solution
- Integrated Digital Thread of PLM and ERP systems
- Battery module-wise recall and containment strategy
- Advanced MES & MOM for real-time manufacturing insights
- End-to-end factory automation and digital integration
- Real-time data collection and analytics for performance monitoring
- Process optimization to enhance efficiency and yield
- Reduced manual intervention for consistent quality
- RPA and AI-driven predictive maintenance
- Advanced traceability for raw materials, components, and finished goods
- Intelligent scheduling and dynamic workflow management
- Use of digital twins and real-time simulations
- Scalable, high-speed, data-driven MES-MOM framework
Key Results and Benefits
- 12% improvement in overall production efficiency
- 40% improvement in compliance reporting
- Real-time visibility from shop floor to top floor via Gen AI-assisted analytics
- Increased user adoption and improved operational decision-making
- Enhanced real-time monitoring and quality control
- Improved product traceability and reduced downtime
About ITC Infotech
ITC Infotech is a leading global technology services and solutions provider, led by Business and Technology Consulting. ITC Infotech provides business-friendly solutions to help clients succeed and be future-ready, by seamlessly bringing together digital expertise, strong industry specific alliances and the unique ability to leverage deep domain expertise from ITC Group businesses. ITC Infotech is a wholly owned subsidiary of ITC Ltd., a 100-plus-year-old diversified conglomerate with businesses spanning Hotels, Consumer Goods, Paperboards & Packaging, Agri Business, and Information Technology. ITC Ltd. has been in the hospitality business for over 4 decades. It has over 100 properties across 70+ destinations. The hospitality practice at ITC Infotech is 800+ people strong and most have experience in the hospitality domain leading to a high-quality IT service experience for its hospitality customers.
