After nearly a year of delving into the intricacies of IT/OT convergence, it's time to shift gears and step into the real world where theory meets practice. Introducing our new series, "Idea to Shop Floor: How companies are figuring out IT/OT Convergence," where we'll be showcasing real-life case studies from companies that are at the forefront of digital transformation. These stories will highlight the challenges, triumphs, and lessons learned from businesses that are successfully (or not) integrating IT and OT, providing invaluable insights and inspiration for your own journey.
In this podcast David talks to Sophie Van Nevel. She is the Global IT Lead for Strategy and Governance and also Data and Analytics at Bekaert.
Established in 1880, Bekaert is a global leader in steel wire transformation and coating technologies. You can find their steel products in various applications: Champagne cork wire, fishhook wire, steel cord inside tires, concrete reinforcement, very specialized applications in renewable energy, fencing and many others.
At Bekaert, you will find various types of industrial processes, one of them is cold drawn steel wire. Cold-drawing changes the steel's shape and size by pulling the material through a carbide die or turks head. Often, steel will go through cold-rolling first and then cold-drawing to enhance its properties for better performance.
Obviously, minimizing energy consumption while increasing the reliability/uptime of the production lines is extremely important for Bekaert. This is where data and Sophie’s team comes into play!
“The basic process is drawing the wire into a smaller diameter, then adding coatings or bundling wires together to create new material properties. This intricate process requires precise measurements and adjustments, making sensor data critical. Sensor data quality is essential to ensure we meet the desired parameters throughout the production process,” Sophie explains.
Building Digital Products
Sophie's team is responsible for creating digital products that leverage data analytics to optimize production processes. This includes using dashboards to monitor energy consumption and employing AI models to refine product quality. “We work closely with our business teams to drive intelligent processes, aiming to optimize our production with the help of technology and data,” Sophie explains. One of their innovative goals is to provide sensor data as a service to their customers, enhancing transparency and collaboration.
The Role of Data Governance
Data governance, often seen as a theoretical concept, is vital for managing both transactional and sensor data. Sophie emphasizes the importance of integrating data governance into everyday practices. “We’ve set up roles like data stewards and custodians, and provide training to ensure everyone understands their role in the data delivery value chain,” she says. This approach ensures high data quality and consistency, which are crucial 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 started by reporting the data from the meters, but soon realized the need for better accuracy,” Sophie recalls. By analyzing discrepancies between machines and understanding the underlying causes, such as temperature changes or data drift, Bekaert was able to develop predictive models to optimize energy use.
Cross-Team Collaboration
At Bekaert, the convergence of IT and OT is achieved through cross-team collaboration. “We bring together IT, business, and engineering teams to solve specific cases, focusing on driving end-to-end value,” Sophie explains. This collaborative approach leverages diverse expertise to tackle complex challenges, such as optimizing energy consumption, and ensures that solutions are practical and effective.
From Services to Manufacturing
Transitioning from a service-oriented organization to a manufacturing environment presented 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, particularly when dealing with existing assets and technology that may not be digital-native. “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. The foundation of 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 the strategic use of data and collaboration.
As we continue this series, we’ll explore more real-world stories to inspire and guide your digital transformation efforts. Stay tuned for more insights from industry leaders who are turning theory into practice.
Find Sophie on LinkedIn.
Further reading:
The Need for Better Data: Why Data Quality is Essential - Part 3 on Industrial Data Platforms
Bridging Data between OT and IT: A Conversation on Data Management with Jan Meskens
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