Engineering + Innovation (Industry 4.0 / Digital Manufacturing)
Digital Manufacturing Strategy & IT/OT PMO
Client · Leading U.S. Beverage Manufacturer
Led the Factory-of-the-Future IT/OT strategy and PMO for a multi-line beverage manufacturing greenfield facility — building the digital backbone for data integration and digital twin enablement.
Outcomes by the numbers
Greenfield facility scope
Workstreams unified under one PMO
Operationalized vision
Future-ready data architecture
The Challenge
A leading U.S. beverage manufacturer needed to realize its Industry 4.0 'Factory of the Future' vision for a new $700M greenfield facility. Digital manufacturing systems lacked unified governance, creating risk of misaligned MES, SCADA, historian, and automation layers — and fragmented OT data infrastructure limiting advanced analytics, digital twin, and AI-driven use cases.
The Approach
Served as IT/OT PMO lead and digital manufacturing strategy advisor, aligning MES, OEE, and ASRS workstreams under a unified program. Defined use-case-driven architecture, including digital water mapping and a unified OT data layer to enable digital twin capabilities. Led Digital Manufacturing Steering Committee decision-making, aligning stakeholders on priorities, architecture, and investment trade-offs. Facilitated vendor alignment, governance cadence, KPI mapping, and cross-functional integration. Bridged IT, engineering, and operations to ensure commissioning readiness.
The Outcome
Established a cohesive digital manufacturing technology strategy aligned to Industry 4.0 objectives, accelerating integration milestones and reducing system and vendor fragmentation risk. Enabled a scalable data foundation for digital twin, AI, and advanced analytics use cases. Positioned the facility for seamless commissioning, faster ramp-up, and long-term operational optimization.
Process Overview
How the engagement actually ran.
Diagnose
Mapped fragmented MES, SCADA, historian and automation layers across IT and OT stakeholder groups.
Design
Built unified governance, KPI mapping, vendor alignment and use-case prioritization.
Execute
Directed multi-workstream IT/OT PMO and governance cadence, aligning vendors, integration, and cross-functional execution.
Accelerate
Established a digital manufacturing governance cadence and data foundation, enabling integration, commissioning readiness, and future AI/ML and digital twin scalability.
All case studies are anonymized to protect client confidentiality.
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