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After nearly a year of exploring the intricacies of IT/OT convergence, it’s time to transition from theory to practice. Welcome to our new series, “Idea to Shop Floor: How Companies Are Navigating IT/OT Convergence.” This series will showcase real-life case studies from companies leading the way in digital transformation. These stories will reveal the challenges, triumphs, and lessons learned in integrating IT and OT, offering valuable insights and inspiration for your own journey.

In this podcast, David speaks with Sophie Van Nevel, the Global IT Lead for Strategy and Governance, and Data and Analytics at Bekaert.

Established in 1880, Bekaert is a global leader in steel wire transformation and coating technologies. Their steel products are used in a variety of applications, including champagne cork wire, fishhook wire, steel cord inside tires, concrete reinforcement, and specialized applications in renewable energy and fencing.

Bekaert employs various industrial processes, including cold-drawn steel wire production. Cold-drawing involves changing the shape and size of steel by pulling it through a carbide die or turks head. This process often follows cold-rolling to enhance the steel’s properties for better performance. Minimizing energy consumption while maximizing production line reliability and uptime is critical for Bekaert. This is where data and Sophie’s team come into play.

“The basic process involves drawing the wire to a smaller diameter, adding coatings, or bundling wires to create new material properties. This intricate process requires precise measurements and adjustments, making sensor data critical. Ensuring sensor data quality is essential to meet the desired parameters throughout the production process,” Sophie explains.

Building Digital Products

Sophie’s team is tasked with creating digital products that leverage data analytics to optimize production processes. This includes using dashboards to monitor energy consumption and employing AI models to improve product quality. “We collaborate closely with our business teams to drive intelligent processes, aiming to optimize our production with the help of technology and data,” Sophie says. One of their innovative goals is to offer sensor data as a service to customers, enhancing transparency and collaboration.

The Role of Data Governance

Data governance is crucial for managing both transactional and sensor data. Sophie emphasizes the importance of integrating data governance into everyday practices. “We’ve established roles like data stewards and custodians and provide training to ensure everyone understands their role in the data delivery value chain,” she notes. This approach ensures high data quality and consistency, which are essential for generating reliable insights and driving business value.

Case Study: Energy Management

A prime example of Bekaert’s data-driven approach is their energy management program. The company installed energy meters in their plants to monitor and reduce energy consumption, aligning with their sustainability goals. “We began by reporting the data from the meters but soon realized the need for better accuracy,” Sophie recalls. By analyzing discrepancies between machines and understanding underlying causes, such as temperature changes or data drift, Bekaert developed predictive models to optimize energy use.

Cross-Team Collaboration

At Bekaert, IT and OT convergence is achieved through cross-team collaboration. “We bring together IT, business, and engineering teams to solve specific cases, focusing on delivering end-to-end value,” Sophie explains. This collaborative approach leverages diverse expertise to tackle complex challenges like optimizing energy consumption, ensuring practical and effective solutions.

From Services to Manufacturing

Transitioning from a service-oriented organization to a manufacturing environment posed unique challenges for Sophie. “In banking, it’s more about services, whereas at Bekaert, the impact of data actions is very concrete and immediate,” she notes. This tangible impact underscores the importance of effective change management, especially when dealing with legacy assets and technology. “We focus on data literacy and involve people in the journey to ensure they see the value of their contributions,” Sophie adds.

Scaling and Sustainability

Scaling digital initiatives from pilot projects to full-scale implementations is a critical aspect of Bekaert’s strategy. Sophie outlines their governance approach, which assesses the value and applicability of pilots across different plants. “Not every plant or product is the same, so we define criteria to determine whether we can scale a digital product,” she explains. This method ensures resources are allocated to initiatives with the highest potential impact while discontinuing those that do not deliver expected results.

The Future of AI and Data at Bekaert

Looking ahead, Sophie is optimistic about the role of AI and data in driving business value. “We hope to continue leveraging AI and data to create significant business value. Data quality and governance will remain crucial as we develop more advanced AI models,” she asserts. Robust data practices will enable Bekaert to harness the full potential of digital technologies, ensuring sustainable growth and innovation. Bekaert’s journey exemplifies how IT/OT convergence can transform traditional manufacturing processes through strategic data use and collaboration.

Stay tuned for more insights from industry leaders turning theory into practice in our continuing series.

Find Sophie on LinkedIn: Sophie Van Nevel

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