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A global medical device manufacturer of innovative orthopaedic solutions, known for precision and innovation, faced operational challenges as growth increased complexity.
Disconnected systems across engineering, manufacturing, planning, and finance hindered data flow. Leadership realized production needed to be traceable, compliant, efficient, and unified—not just innovative in design.
To meet regulatory standards and remain competitive, the company partnered with Birlasoft to create an AI-powered, integrated digital ecosystem for modernized manufacturing.
The Challenge
As Birlasoft evaluated the situation, it found that fragmentation—not lack of capability—was the main constraint.
- Data Silos: Legacy systems led to separated data environments, so PLM, MES, and ERP each function independently, restricting visibility and collaboration across teams
- Compliance Pressures: Intercompany transfers, lot number etching, and traceability were not standardized. With stricter FDA and global compliance, recall readiness and audit response faced increased scrutiny
- Technical Debt in PLM: The Windchill PLM system became inflexible due to outdated libraries, a monolithic architecture, and insufficient documentation, limiting agility and slowing improvements
- Operational Inefficiencies: Changeovers took too long. Scrap and rework exceeded expectations. Manual handoffs caused errors and delayed launches
These challenges went beyond productivity, harming product quality, compliance confidence, and market speed—key factors for a medical device manufacturer’s competitiveness.
The Transformation
Instead of simply addressing individual symptoms, Birlasoft implemented a comprehensive digital manufacturing ecosystem designed to eliminate silos and incorporate intelligence throughout the value chain.
The integration of systems served as the cornerstone of this approach: Birlasoft consolidated PLM, MES, and JDE ERP into a closed-loop manufacturing framework. Design specifications were transferred seamlessly from PLM to MES, while production data was relayed back to engineering systems. Business planning and enterprise-level decisions were synchronised with real-time shop-floor insights.
This initiative represented more than system integration—it achieved true operational alignment.
Connecting MES to PLM specifications enabled real-time quality management. Production data was checked against design parameters, allowing early detection of deviations and reducing defects. Engineers and plant managers shifted from reacting to proactively preventing issues.
Change management saw significant progress. Engineering updates to designs were instantly visible to manufacturing, enabling production teams to respond swiftly without delays from manual paperwork or repetitive communication. Product launches accelerated as design and production collaborated seamlessly via shared digital tools.
Resource utilization was enhanced. AI-driven scheduling facilitated optimal allocation of labor, equipment, and materials. Redundancy was minimized, project delays were reduced, and energy consumption patterns were identified, supporting more informed optimization strategies.
Modernizing Windchill PLM resolved technical debt, improved architecture and documentation, enabling faster updates and less risky enhancements.
The result was a smart manufacturing platform. Model-based enterprise practices maintained consistent data throughout the product lifecycle, ensuring accurate information from design to delivery.
The Impact
The transformation resulted in quantifiable improvements across the enterprise in efficiency, quality, and compliance.
- Up to 25% reduction in operational expenses through optimized resource allocation
- 15–25% lower energy consumption across production facilities
- Up to 30% improvement in overall production efficiency
- Up to 50% faster changeovers, reducing downtime between product runs
- 40–60% reduction in scrap and rework due to real-time quality checks
- 100% material and product traceability, strengthening regulatory compliance
- 2X faster decision-making enabled by integrated MES-PLM workflows
- 20–35% quicker time-to-market for new product introductions
These improvements were cumulative: quicker changeovers boosted capacity, cut waste, and raised margins; real-time traceability enhanced compliance and recall readiness. Decision-making became proactive, with leaders acting on live data instead of waiting for reports.
The Outcome
The global medical device manufacturer of innovative orthopaedic solutions moved from fragmented workflows to a connected, coordinated execution model. Design, production, and enterprise planning now operate within a unified ecosystem where data flows automatically, quality checks occur in real time, and compliance is built into daily operations—not added at the last minute.
The benefits were felt across leadership roles:
- For the VP of Manufacturing: End-to-end visibility across plants improved operational control and strategic planning. Standardized processes, real-time performance metrics, and optimized resource utilization strengthened margins and enabled faster scaling of new product launches
- For the Head of Quality: With 100% material and product traceability embedded into the system, compliance became proactive rather than reactive. Real-time validation reduced scrap and rework, while audit readiness and recall response times improved significantly
- For the Plant Manager: Shop-floor execution became smoother and more predictable. Faster changeovers, clearer digital work instructions, and unified dashboards reduced manual effort and improved daily decision-making
Operationally, the company gained synchronized execution and measurable efficiency improvements. Strategically, it built a scalable digital backbone ready for future AI initiatives.
By integrating AI, PLM, MES, and ERP into one intelligent ecosystem, the organization transformed manufacturing into a core driver of innovation—creating a compliant, efficient, and future-ready environment built for sustained growth.
