Case Study

Digital Transformation in the Fiber Glass Industry

The client is a leading producer in the fiber glass industry, operating at a capacity of 22,000 MTPA. With
increasing market demand, they planned to expand their production capacity to over 100,000 MTPA.

Business Challenges

The client was facing multiple business and technical challenges:

High market demand and business opportunity worth $2.1 billion (as per Lenzinger reports)

Need for faster time-to-market without compromising quality

Requirement for scalability to support multiple products

High system downtime affecting productivity

Lack of visibility and integration across systems

Need for future readiness for ERP/MES integration

Softcon's Proposed Solution

Softcon provided a comprehensive automation and control solution using Rockwell Automation's PlantPAx DCS and other technologies. The key components included:

PlantPAx Distributed Control System with Flex 5000 IO

Plantwide DLR (Device Level Ring) Network to ensure zero downtime

Controller-based Batching Solution for consistent quality

Redundant HMI Servers with Thin Clients for future scalability via ThinManager

High-level DLR with seamless third-party integration

Optimized engineering development, saving up to 50% in development time

System Highlights

Speed to Market: Engineering development time reduced by 50%

System Network: High availability with zero downtime due to robust DLR network

Quality: Batch rejection reduced by 50%

Integration: Seamless communication with third-party systems via OPC Server

Plant Visibility: Real-time data available at both plant and process level

User Interface: Centralized and intuitive system dashboard

Impact & Business Outcomes

Metric

Improvement

Execution Time

Reduced by 20%

Downtime

Reduced by 45% due to E&I improvements

Asset Utilization

Improved by 40% through multi-product flexibility

Decision Making

60% faster with real-time visibility

Raw Material Stock

Reduced by 28% due to better visibility

Future Savings

$120,000 saved by avoiding rework for ERP/MES readiness

Conclusion

Softcon successfully enabled the client to scale their operations from 22K to 100K MTPA while ensuring
quality, efficiency, and future scalability. Through a robust automation system and smart manufacturing
practices, the client is now better prepared to meet growing market demands, improve productivity, and
reduce operational costs.

Neeta Kulkarni

Head Projects

Neeta Kulkarni

Director of Execution, Softcon

Neeta Kulkarni is a results-driven leader with a proven track record in executing strategic initiatives, optimizing operations, and driving organizational success. With [X] years of experience in Softcon, she specializes in aligning business objectives with efficient execution frameworks to maximize performance and growth.

Her leadership approach is centered on strategic execution, operational efficiency, and continuous improvement. She is dedicated to translating vision into action, ensuring that teams work seamlessly toward achieving measurable goals. With a focus on making the company more efficient and goal-oriented, Neeta Kulkarni plays a key role in driving long-term success.

Vinayak Hegde

Director Sales

Vinayak Hegde

Director Sales, Softcon

Vinayak is a seasoned professional with many years of experience in creating strategic roadmaps, driving corporate growth, and delivering impressive results. He has led high-performing teams and managed diverse responsibilities, significantly increasing annual revenues for multinational companies. His innovative approach has helped companies like Siemens and GE double their revenue in record time by breaking into competitive markets.

An expert in IIoT-connected enterprise solutions and product management, Vinayak is a true source of wisdom in automation, people management, and thoughtful leadership. His dedication to quality and continuous improvement consistently propels groundbreaking achievements across various industries, making him a key force in transforming business challenges into growth opportunities.

Chintamani Unde

Service Head

Chintamani Unde

Service Head, Softcon

Chintamani Unde is a seasoned leader responsible for overseeing the entire maintenance and drives repair department, bringing extensive expertise and unwavering passion to his work.

With a strong background in managing large-scale service teams and optimizing repair processes, he consistently drives operational excellence and innovation. His strategic approach has reduced service downtime, improved customer satisfaction through proactive maintenance strategies, and optimized operational costs without compromising quality.

Chintamani’s commitment to translating vision into action and his ability to lead cross-functional teams ensure that the organization upholds high standards of quality and reliability, making him essential to boosting customer happiness and overall service performance.

Umesh Kulkarni

Project Director

Umesh Kulkarni

Project Director, Softcon

Umesh Kulkarni is the CEO and the driving force behind our smooth operations. With many years of experience, he has built a team that works together efficiently to reach clear goals.

Umesh is known for his practical approach to solving problems and improving everyday work. He focuses on turning ideas into simple, clear actions that help the company grow and succeed. His strong leadership and dedication to continuous improvement have made the company a leader in the industry.

Umesh’s hands-on style ensures that every part of the business works well, creating a culture of steady progress and success.

Mansing Beloshe

Head Projects

Mansing Beloshe

Head Projects, Softcon

Mansing Beloshe is an experienced Project Manager with a strong background in the industrial automation industry. With expertise in Process Control, Engineering, Control Systems Design, Process Automation, and Project Engineering, he has successfully led numerous projects, driving efficiency and innovation.

His strategic approach to program and project management ensures seamless execution, from planning to implementation. A graduate of Sanjween Vidhyalay, Panchgani, Mansing is committed to delivering high-quality automation solutions that enhance operational performance and reliability.

Chintamani Unde

Service Head

As a Senior Manager for Service & Repair at Softcon Systems Pvt. Ltd., Chintamani Unde contributes knowledge and a commitment to providing outstanding service solutions.

Chintamani is essential to boosting customer happiness and upholding the organization's high standards of quality because of its emphasis on streamlining repair procedures and guaranteeing operational excellence.

Vinayak Hegde

Director Sales

Vinayak Hegde is a seasoned professional with 26 years of experience in creating strategic roadmaps, accelerating corporate growth, and producing significant outcomes. He has effectively led high-achieving teams, handled a variety of activities, and overseen yearly revenues of INR 60 crores. Vinayak has been instrumental in helping Siemens and GE double their revenue in record time by using creative tactics to break into cutthroat sectors.

He is an expert in IIoT, linked enterprise solutions, and product management, and he was awarded the Best Project Award at IIM Bengaluru. He also provides automation knowledge and thought leadership. Vinayak's dedication to quality keeps propelling revolutionary achievement in a variety of sectors.

Chandrakant Kulkarni

Managing Director

Chandrakant Kulkarni

Managing Director, Softcon

Chandrakant Kulkarni holds a degree in Electrical Engineering and Management, which laid the foundation for his technical and entrepreneurial journey. His early roles in small companies helped him develop expertise in operations, marketing, and technology, ultimately paving the way for him to establish his own company within a decade.

Initially specializing in power management and process automation, his venture expanded over 22 years into IoT, motion control, and end-to-end integration. His leadership is driven by a relentless passion for innovation and solving complex challenges, creating significant value for customers and stakeholders.

With a visionary approach, Chandrakant Kulkarni continues to inspire industry transformation, setting new benchmarks in technological advancements and business excellence.