The digital transformation challenge: sponsorship and investment persist, but adoption and maturity are low.
7 in 10 companies are piloting, implementing or using the digital thread yet 60-80% of projects fail. Initiatives are taking twice as long and costing twice as much as expected. And the performance gap between those that succeed and those that don’t is growing.
Visit our team in booth #1240 at Automation Fair to learn how we help manufacturers transition from creating incremental benefit to driving transformational change. Kalypso’s interactive Digital Manufacturing Assessment will demonstrate the methodology for bringing autonomous operations to life, using our proven digital thread assessment to guide manufacturers on a path forward, defined by high impact use cases.
We help you avoid the pitfalls and show business value quickly to create momentum.
Achieve what’s possible in Digital Manufacturing with Kalypso.
Kalypso is Rockwell Automation’s digital services arm.
Our people are innovators, strategists, data scientists and technologists. Product people, with plant-floor expertise.
We bring digital solutions to product problems.
- Speed time to market
- Improve quality
- Increase plant yield
- Ensure compliance
- Reduce waste
- Increase profitability
Case Study / First Solar: How we helped First Solar ramp faster and deliver better outcomes for sustainable energy with digital twin virtual commissioning of their flagship factory
15% OEE increase during ramp-up
40% reduction in commissioning time
Reduced Capex investment
Increased training efficiency & efficacy
Reduced risk by running ‘what-if’ scenarios
How we helped First Solar ramp faster and deliver better outcomes for sustainable energy with digital twin
First Solar has created a superior digital representation of its material handling system, enabling them to test changes and expansions virtually, as well as predict and prevent operational disruptions.Read More
Case Study / Newcrest Mining: Model Predictive Control for More Efficient Mining
Reduced power usage
Improved process stability
Increased gold recovery
How We Helped Newcrest Mining Maximize Efficiency and Profitability Across Processing Plants with Model Predictive Control
In pursuit of greater efficiency and profitability, Newcrest embarked on a multi-year Process Control & Analytics (PC&A) initiative in partnership with the Kalypso Industrial Data Science team. The forward-thinking PC&A framework strategically combined internal skill enhancement with external collaboration, empowering the deployment of cutting-edge technologies including AI and advanced process controls to revolutionize Newcrest's operations.
Newcrest engaged the Kalypso Industrial Data Science team to explore how Pavilion8® model predictive control (MPC) technology could be deployed in its process plants to achieve key targets. The joint efforts of the Newcrest and Kalypso teams yielded improvements that not only met but often more than doubled the initial targets set, delivering significant and ongoing economic and environmental benefits.Read More
Case Study / Industrial Manufacturing: Building Better Tires with AI
45% reduction in down time
100+ more tires per machine per day
550,000 more tires per year
How we helped a major tire manufacturer make half a million more tires each year
Kalypso was brought in by the client to evaluate their tire production with the goal of reducing down time with the help of AI. We trained an algorithm to predict bad splices before they happen and prescribe pressure setting adjustments via the interface to the machine control system, programmatically bringing the splice within tolerance. Our work made it possible to make over half a million more tires every year.Read More
Our Sessions at Automation Fair
Subject matter experts from Kalypso are participating in panels, showcasing customer success stories and presenting real world guidance for manufacturing transformation.
CV03 - How Newcrest Mining Improved Productivity at Three Goldmines with Model Predictive Control
Newcrest Mining Ltd. engaged Kalypso to implement model predictive control (MPC) using Pavilion software at three locations. By developing MPC applications for Newcrest's grinding, concentration and flotation circuits, we helped the client improve process stability, throughput and gold recovery.
Tue, Nov 7, 2023 @ 10:00 AM
CV04 - How Thermo Fisher doubled 7-day OEE and Made Other Gains by Harnessing its Production Data
Thermo Fisher is using Digital Performance Management (DPM) and services from Kalypso to enhance real-time production visibility and accelerate performance improvement in its bio-pharmaceutical operations. Results include increased OEE and generating $5 million more in revenue from a single line.
Tue, Nov 7, 2023 @ 11:00 AM
CV17 - Cimento Itambe Use Case – Process Improvements using FactoryTalk® Analytics™ Pavilion8®
In this session, you will gain insights on cement process optimization using advanced analytics solutions like Model Predictive Control (MPC). Cimento Itambe will share how they enhanced efficiency, reduced energy consumption and improved product quality, reusing in cost savings and increased competitiveness. Hear about their experience, requirements and results achieved over the last 2 years working with the Pavilion system.
Tue, Nov 7, 2023 @ 9:00 AM
IE18 - Digitization of Asset Inspection Using IIoT, Digital Twin and Automated Robots
Join Kalypso and our robotics partner Taurob to hear how IIoT, digital twin and automated robots can support Oil & Gas operators to digitize and automate asset inspection and maintenance activities on industrial assets.
Speakers: Matt Graves, Guillaume Chevet, Matthias Biegl (Taurob)
Mon, Nov 6, 2023 @ 11:00 AM
Wed, Nov 8, 2023 @ 3:00 PM
IE74 - The Industrial Metaverse: Rockwell Automation, Microsoft Explain the Journey to Immersive Reality
According to ABI Research, revenues for industrial digital twin, simulation and extended reality will hit $22.73 billion by 2025. Experts from Microsoft and Rockwell Automation will explain the basics of digital twins and the industrial metaverse and why it matters today. As other companies try to envision the metaverse for consumers, the industrial metaverse is already transforming how people design, manufacture and interact with their physical world. Learn how enterprises can unlock the potential of the industrial metaverse; What are digital twins? Why are people talking about metaverse today? What are major opportunities for manufacturers? What technologies are essential?
Tue, Nov 7, 2023 @ 2:00 PM
Thur, Nov 9, 2023 @ 10:00 AM
PT12 - The Smart Way to Conserve Your Energy and the Environment
This session will explore digital solutions that provide you with a deeper visibility into performance and energy consumption – from the granular component level to the machine level to the enterprise level – enabling you to fine-tune energy consumption, based on real-time diagnostics and alerts.
Tue, Nov 7 2023 @ 9:00 AM
Thur, Nov 9, 2023 @ 4:00 PM
PT52 - Taking Your DCS from Chasing Disturbances to Achieving Autonomous Operations
Looking to drive more value out of your process control system? Struggling with operator knowledge gaps putting your plant operations at risk? Model Predictive Control (MPC) leverages your existing regulatory control to optimize your process by layering models above your DCS to achieve better production, quality and profitability. Hear from Rockwell Automation on real case studies where process customers have applied MPC to drive value. Learn how MPC can help empower your operators to go from managing minute-to-minute process disturbances to achieving autonomous operations.
Tue, Nov 7, 2023 @ 1:00 PM
Thur, Nov 9, 2023 @ 11:00 AM
ESG Summit: Net-Zero Now
We believe in the power of possibility. Understanding that no company can tackle global climate challenges alone, true possibility lies in collaboration, working together to deliver new ESG solutions that make the world work better for people and planet. This exclusive Summit will provide you with access to knowledge exchanges and thought leadership conversations that can help you solve common industrial net-zero challenges around energy, water, and waste now.
Rodrigo Alves, Cariappa Monaiah
Mon, Nov 6, 2023 @ 12:00–5:00 PM
Related Thought Leadership
Get to Know Our Team
Meet some of the Kalypsonians who will be presenting sessions and showcasing our work on the Expo floor at Automation Fair. Connect with our thought leaders to discuss your goals, get inspired by some of the work they are doing and put a plan together to achieve the results you're targeting.