Brilliant Factories Are Making Manufacturing Pretty Brilliant

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Capgemini is partnering with GE to help industrial companies accelerate their Industrial Internet of Things journey.

Business data today is growing twice as fast as data in any other sector and it is estimated that by 2020, over 50 billion assets will connect to the Internet. To thrive in this dynamic environment, businesses must have the ability to rapidly and effectively turn these overwhelming amounts of data into actionable insights.

For industrial companies, this can be a formidable challenge. That’s why GE created Predix, an industrial internet platform that answers the unique needs of industrial enterprises on the path to digitization. It’s also why Capgemini is partnering with GE to help industrial companies optimize their Predix implementation and accelerate their Industrial Internet of Things (IIoT) journey. This partnership brings together a potent combination of GE Digital’s Industrial Internet vision and Capgemini’s proven track record of business consulting and systems integration.

Together, they are ushering in a new era of industrial internet with their Brilliant Factories initiative, which is based on the Predix platform. This initiative allows industries a single, secure way of gathering data from a variety of assets to create a comprehensive and validated data repository that can be used to generate actionable insights.

Today, an increasing number of manufacturers are moving towards “Smart Factories” or factories which leverage emerging digital technologies such as the Internet-of-Things, Big Data Analytics, Artificial Intelligence, Robotics, 3D printing, and Cloud computing along with smart features to gain considerable advantage in terms of productivity, efficiency, quality, and flexibility. A recent Capgemini survey found that nearly half of all manufacturers surveyed had an operational smart factory initiative while another 33% were in the process of formulating an initiative.

As a matter of fact, the size of the smart factory prize is simply too big to ignore. According to the United Nations National Accounts Main Aggregates Database, smart factories could add between $500 billion to $1.5 trillion in value added to the global economy in five years. Similarly, manufacturers predict overall efficiency to grow annually over the next five years at seven times the rate of growth since 1990. As discussed in the Capgemini report “Smart Factories: How can manufacturers realize the potential of digital industrial revolution,” the projected benefits are numerous and yet, significant challenges exist in fully realizing all of these benefits.

Capgemini found that while 76% of manufacturers either have a smart factory initiative that is ongoing or are working on formulating it, only 14% of companies are satisfied with their level of smart factory success. In our survey, we found that only 6% of manufacturers could be classified as “Digital Masters,” companies at an advanced stage in digitizing production processes and with a strong foundation of vision, governance, and employee skills. And it is these digital masters who outpace all others in terms of benefits realized. For instance, in productivity benefits alone, digital masters have realized an average 24% improvement, outperforming the others.

So how do companies make the jump towards becoming “Digital Masters?” The Brilliant Factories initiative brought to you jointly by Capgemini and GE can help. The software focuses on empowering decision makers with real-time visibility and deep operational intelligence, thus supporting decision making with real-time quality and execution information. In this context, an important use case comes from Capgemini Italy, where we partner with GE Oil and Gas to build the smart shop solutions applications. Capgemini is strongly investing and collaborating with GE on building the new digital revolution and proposing to the open industrial market the Smart Shop Solutions into the Brilliant Factory Context. The Brilliant Factory is a concept and IP developed by of GE itself, based essentially upon three main pillars.


Bridge the information gap between Engineering and Manufacturing via Digital Tools


Enable higher uptime and quality at each individual manufacturing machine tool


Increase throughput and inventory turns by enhancing data visibility at factory level and  in the Supply Chain

This solution helped GE Oil & Gas overcome several pressing challenges such as the lack of visibility of plant/lines performance, no real-time control on work centers production and maintenance status, production owners not receiving info with the right level of detail to enable action and the less than complete visibility of a moving part across the complete supply chain.

The Brilliant Factory Smart Shop

  • Allowed dashboarding at machine, line and plant level,
  • Provided real-time plant, machine and faults reason control, and
  • Presented a plant scorecard.

This initiative was also recently showcased by Capgemini, GE Oil & Gas, and GE Digital at the event SAVE Milano. SAVE Milano—Conference and Exhibition on Solutions and Applications for Automation, Instrumentation, Sensors is an event which combines an exhibition with vocational training. The session, which was well-received, was held as part of the L’Asset Management nel Manifatturiero Intelligente (Asset management in the Intelligent Manufacturing) workshop. During the session, Antonio Ziliani, VP Italy Head of Practice Solutions—GE Italy and Eastern Europe Account Executive at Capgemini, Donatella Banchi, O&G TPS CIO for GSC, Quality and HSE, and Corrado Giussani, Channel & Alliances Manager Southern Europe at GE Digital, presented the Brilliant Factories concept in front of an audience of hundreds of CIOs & technical specialists belonging to the Manufacturing, Food, Energy, and Utilities industries.

The Capgemini–General Electric partnership is more than 25 years old and this presentation, which saw our first joint marketing participation is proof of our commitment towards industrial digitization. This was also the first time that the Brilliant Factory model was presented in Italy, a region in which our commitment is set to deepen further in the coming years, as we move beyond Italy to the Eastern European countries with our IIoT offerings.

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