A global leader in the energy and lubricants industry was facing rising operational risks at its advanced manufacturing facility in Jebel Ali, Dubai. Issues ranging from counterfeit products and export compliance concerns to inefficiencies in manual production processes were impacting growth and profitability. By partnering with Innobayt, the company implemented a custom smart factory platform—connecting legacy equipment, digitizing workflows, and enhancing real-time visibility. The result: reduced downtime, improved supply chain traceability, and measurable business impact.

The Challenge

Despite being equipped with modern infrastructure, the facility faced:

• Counterfeit risk in key markets, with no means for customers or distributors to verify product authenticity.

• Export compliance gaps, as untraceable products occasionally appeared in restricted regions.

• Manual labeling and rejection handling, leading to delays and frequent stoppages on the production line.

• Disjointed systems, including SAP, spreadsheets, and email, creating operational silos.

• Lack of real-time visibility, limiting agility in decision-making and response.

To overcome these barriers, the company needed a unified, IoT-enabled digital layer that could streamline operations and safeguard compliance.

The Solution

Innobayt conducted a series of workshops with stakeholders to understand operational pain points and designed a smart factory solution tailored to the facility’s needs. Key features included:

• End-to-End Product Authentication: Unique QR codes were assigned to every bottle, carton, and pallet using OCR-enabled scanning and SAP-integrated workflows. Customers could verify authenticity via mobile/web apps.

• Traceability Engine: Supply chain visibility was enhanced across all packaging levels, enabling origin tracking in cases of unauthorized distribution.

• Legacy System Modernization: PLCs and custom middleware connected conveyors, weight rejectors, printers, and sensors into one synchronized platform.

• Real-Time Operator Interface: Tablet-based control panels enabled operators to manage production, reprint labels, and resolve issues proactively.

• Remote Oversight & Insights: A web-based admin panel and dynamic dashboards offered real-time visibility into throughput, downtimes, and audit logs.

• Hybrid Deployment Model: The platform was deployed both on-prem and in Azure, ensuring scalability and local reliability.

Business Impact

The transformation brought significant improvements across operational, compliance, and financial dimensions:

• Counterfeit Reduction: 70% decrease in fake product circulation, restoring market share

• Compliance Assurance: 90% fewer violations, avoiding substantial legal risks

• Downtime Reduction: 50% drop in line stoppages, saving 20 hours per week

• Throughput Increase: 35% rise in production, adding 150,000 bottles monthly

• Inventory Accuracy: 95% improvement in rejection tracking

• Decision-Making Speed: 40% faster insights through real-time dashboards

• Market Confidence: 25% increase in distributor order volume within six months