Loading
myRockwellAutomation
Careers
Investors
PartnerNetwork Portal
Contact Us
Popular Resources
Compatibility & Downloads (PCDC) Knowledgebase Literature Library Lifecycle Status Learning+ Training Portal
 
Product Management
Asset Management (RAAMP) Installed Base Evaluation (IBE) My Equipment Self-Service Product Registration Repairs Service Contracts & Tickets Software Activation Software Subscriptions Sustainability Dashboard
 
Product Configuration and Selection
Advisor Bill of Materials CrossWorks Integrated Architecture Builder Product Catalog ProposalWorks Proposal Builder ProposalWorks Standards Builder Safety Automation Builder
 

 

View All Tools →

InformationInformation
This content is not available in your selected language.
Rockwell Automation logo
Products
Hardware
What's New in Hardware
Circuit & Load Protection Condition Monitoring Connection Devices Distributed Control Systems Drives Energy Monitoring Human Machine Interface (HMI) Independent Cart Technology Industrial Computers & Monitors Industrial Control Products Input/Output Modules Lighting Control
Motion Control Motor Control Network Security & Infrastructure Packaged Solutions Power Supplies Programmable Controllers Push Buttons & Signaling Devices Relays & Timers Safety Instrumented Systems Safety Products Sensors & Switches Signal Interface
Software
What's New in Software
Cloud Software
 
Design
Studio 5000 FactoryTalk Logix Echo Emulate3D Digital Twin Arena Simulation FactoryTalk Design Studio FactoryTalk Twin Studio FactoryTalk Vault
 
Analytics & Data
FactoryTalk Historian FactoryTalk Analytics FactoryTalk Analytics LogixAI FactoryTalk DataMosaix FactoryTalk Energy Manager Thingworx IIoT FactoryTalk Transaction Manager FactoryTalk Edge Manager Model Predictive Control
HMI
FactoryTalk View FactoryTalk Optix
 
MES
Plex MES FactoryTalk ProductionCentre FactoryTalk PharmaSuite Plex MES for Food & Beverage FactoryTalk CPGSuite Plex Quality Management System Plex Enterprise Resource Planning Plex Asset Performance Management Plex Production Monitoring Finite Scheduler FactoryTalk EIHub
 
Performance Monitoring
FactoryTalk Metrics OEE
 
Thin Client Management
ThinManager
Maintenance
Fiix CMMS FactoryTalk Analytics GuardianAI FactoryTalk AssetCentre FactoryTalk Remote Access FactoryTalk Network Manager Emonitor
 
Process
PlantPAx FactoryTalk Batch
 
Industrial Communications
FactoryTalk Linx
 
XR/Augmented Reality
Vuforia
Product Directory Allen-Bradley FactoryTalk
Services
Asset Optimization & Workforce Services
Asset Optimization Services Overview Equipment Repair Equipment Remanufacturing Repair and Inventory Agreements Integrated Service Agreements Remote Support & Monitoring Onsite & Field Services Safety Services Training Services
Cybersecurity & Network Infrastructure
Cybersecurity Industrial Network Infrastructure Pre-Engineered Network Solutions
Digital Thread
Overview
Production Automation
Overview Coordinated Drive System Solutions
Loading
LifecycleIQ Services
Solutions & Industries
Solutions
Advanced Motion & Robotics Asset Management Cybersecurity Data Operations & Analytics Digital Thread Digital Transformation Industrial Automation Control Industrial Components Networks & Infrastructure On-Machine Solutions
Packaged Solutions Process Solutions Production Automation Production Operations Management Safety Solutions  Scalable Control & Visualization Smart Manufacturing Sustainable Solutions Workforce Enablement
 
Solutions for
OEMs
Industries
Automotive & Tire Cement Chemical Entertainment Fiber & Textiles Food & Beverage Household & Personal Care Hydrogen Infrastructure Life Sciences
Marine Metals Mining Oil & Gas Power Generation Print & Publishing Pulp & Paper Semiconductor Warehouse & Fulfillment Water Wastewater
Loading
View Case Studies
Support
Documentation
Technical Documentation Center Product Drawings & Wiring Diagrams Product Certifications Release Notes Technical Specifications
Product Support
Downloads Selection & Configuration Management
Training
Webinars Workforce Development Training Instructor-led Courses Certificate Programs Job Aids Training Workstations Learning+ Training Subscriptions
Contact Us
TechConnect Support Customer Care Software Portal Help General Inquiries
TechConnect Support
TechConnect Support

Get the knowledge and assistance for solving your technical challenges.

Learn More about TechConnect
Compatibility and Downloads (PCDC) Knowledgebase Literature Library Engage Online Community
Sales & Partners
Find a Partner
Go to the Partner Finder
 
Our PartnerNetwork
PartnerNetwork Program Digital Partners Distributor Partners Licensed Developers
Original Equipment Manufacturer (OEM) Partners Strategic Alliance Partners System Integrator Partners Technology Partners
Order Online
Software Subscriptions E-learning Training Instructor-led Training Learning+ Training Subscriptions
What is the PartnerNetwork™?
What is the PartnerNetwork™?

Our Rockwell Automation PartnerNetwork™ program gives our customers access to the best people, products, services and solutions to meet manufacturing goals and bring The Connected Enterprise to life.

Explore Now
myRockwellAutomation
Careers
Investors
PartnerNetwork Portal
Contact Us
Resources
Popular Resources
Compatibility & Downloads (PCDC) Knowledgebase Literature Library Lifecycle Status Learning+ Training Portal
 
Product Management
Asset Management (RAAMP) Installed Base Evaluation (IBE) My Equipment Self-Service Product Registration Repairs Service Contracts & Tickets Software Activation Software Subscriptions Sustainability Dashboard
 
Product Configuration and Selection
Advisor Bill of Materials CrossWorks Integrated Architecture Builder Product Catalog ProposalWorks Proposal Builder ProposalWorks Standards Builder Safety Automation Builder
 

 

View All Tools →

Select country or region
  • Sweden
  • Argentina
  • Australia
  • Belgique | Belgium
  • Brasil
  • Canada
  • Colombia
  • Czech Republic
  • Denmark
  • Deutschland
  • España
  • Finland
  • France
  • Hungary
  • India
  • Indonesia
  • Ireland
  • Israel
  • Italia
  • México
  • Netherlands
  • New Zealand
  • Norway
  • Poland
  • Portugal
  • Puerto Rico
  • Romania
  • Russia
  • Schweiz | Suisse
  • Singapore
  • South Africa
  • Turkey
  • Ukraine
  • United Arab Emirates
  • United Kingdom
  • United States
  • Österreich
  • 中国
  • 台灣, 中國
  • 日本
  • 한국
Select language
  • English
  • Deutsch
  • Español
  • Français
  • Italiano
  • Português
  • 日本語
  • 简体中文
  • 繁體中文
  • 한국어
Sign In Create an Account
Why Create an Account?
Create bills of materials, submit repair quotes, register products and more!

Manage your e-communication subscription preferences.

Manage your user profile.
Welcome, {0}
Residing Location
My Account Sign Out
Your recent searches
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
  • HistoryHistory
    CloseClose
All
Products
Documents
Downloads
Suggested search terms
  • SearchSearch
  • SearchSearch
  • SearchSearch
  • SearchSearch
  • SearchSearch
  • SearchSearch
Results for "{0}"
View all results
Product results for "{0}"
Product Image
Product Image
Product Image
View all product results
Document results for "{0}"
Portable Document Format.pdf file type
Publication Type: Published Date: Language:
Portable Document Format.pdf file type
Publication Type: Published Date: Language:
Portable Document Format.pdf file type
Publication Type: Published Date: Language:
View all document results
Download results for "{0}"
DownloadDownload
Catalog Numbers:
DownloadDownload
Catalog Numbers:
DownloadDownload
Catalog Numbers:
View all download results
Case Study | Digital Transformation Thought Leadership
Recent ActivityRecent Activity
3 minute read

Caterpillar Unearths Data to Improve Critical Production Processes

The equipment maker used a rapid IIoT deployment to gain data-based insights and optimize production at a components plant. Now, the company is taking the deployment global.

Share This:

LinkedInLinkedIn
XX
FacebookFacebook
PrintPrint
EmailEmail
Front load equipment on a site scooping minerals

Caterpillar

equipment imprinted with the iconic “CAT” logo is a hallmark on job sites defined by grit and hard work – from building construction sites to rugged and remote mines.

Helping give Caterpillar equipment the durability its users expect is the company’s Advanced Component Manufacturing Division. The internal manufacturing group makes transmissions, hydraulic components and other parts for the machine and aftermarket businesses of Caterpillar.

Recently, the division embarked on a project to create not a new part, but rather something less tangible: data-driven insights about its production operations.

Video Player
Chevron DownChevron Down Chevron DownChevron Down
Caterpillar IIoT Deployment Generates Rapid Operational Insights and Business Impact
00:00
00:00
00:00
Use Up/Down Arrow keys to increase or decrease volume.

Shining a light on 'black box' operations

Accessing production data would open up new possibilities for the component division.

Its critical manufacturing processes were “black box” operations. This meant workers had no data proving that the process and product were actually meeting engineering specifications. The lack of data also resulted in inefficiencies and sub-optimal processes, which ultimately drove rework and other non-value-added costs.

“Our goal was twofold,” said Brent Ruth, global ACM ERP CoE Leader, Caterpillar. “First of all, we wanted to learn how to connect and utilize IIoT devices within our factory environment and get some quick wins. And secondarily, we wanted to gain insight into our actual manufacturing processes to include understanding what is happening in real time to be able to improve and optimize our process and efficiency.”

Starting the journey

An initial proof-of-concept took place over a blistering four weeks before Christmas. The goal? Capture PLC data from critical-constraint machines and present it with graphical analysis to manufacturing engineers, all of which would be done using the FactoryTalk InnovationSuite, powered by PTC

.

For the project, Ruth built a team that brought together deep technical and process expertise, while also leveraging the support of Rockwell Automation and PTC. Team members came from IT and OT backgrounds that historically have had competing priorities. But they were able to work together because they both understood the vision of the project and were involved in executing it.

“We formalized collaboration between IT and OT through direct interaction,” Ruth said. “We did this by really rolling up our sleeves and working together as one team, all the way from refinement of strategy and vision up front, to project execution, and every step in between. By doing this, we were able to forge strong working partnerships.”

“We formalized collaboration between IT and OT through direct interaction,” Ruth said. “We did this by really rolling up our sleeves and working together as one team, all the way from refinement of strategy and vision up front, to project execution, and every step in between. By doing this, we were able to forge strong working partnerships.”


To generate and prioritize use cases, the team spent weeks on-site at plants to assess their readiness for digital transformation. They plumbed ERPs, dove deep into master data, and looked at how business was conducted both in the back office and on the shop floor. All this helped the team develop and prioritize digital initiatives that were aligned to business needs and goals.

“During those initial stages, we took a lot of time to engage our local business and finance people in quantifying the benefits and making sure that we had really good estimates based on industry, and also agreed assumption,” said Haydn Powell, global supply chain manager, Caterpillar.

A watershed moment

Creating operational insights and proving that production was indeed meeting engineering specs was a “watershed moment” for the component division.

With access to rich data context that it never had before, the division was able to see all of the non-value-added time in the process. And manufacturing engineers were able to improve and optimize the process quickly. So quickly, in fact, that they reduced overall process time by over 5% on day one.

Several hundred thousand dollars of cost were also saved by showing the plant didn’t need to add assets or shifts. Capacity was available after all – the division just needed the data to prove it.

Meanwhile, this early success proved to be just the start. The project scope was expanded beyond the critical-constraint machines to include the rest of the plant and other domestic and international plants.

“This work has been very instrumental in defining our future direction,” Powell said. “The initial sprint that we accomplished was done in weeks. And the current activity is continuing, because it’s really part of a journey.”

Learn more about Digital Transformation

Topics: Mining FactoryTalk InnovationSuite
Subscribe

Subscribe to Rockwell Automation and receive the latest news, thought leadership and information directly to your inbox.

Subscribe

Recommended For You

MES for Metals
Grinding a metal part in an industrial facility
Software
MES for Metals

Learn how a modern MES can help solve metals industry challenges.

Get Started
Connect people to information: when they need it most
Interactive software used on a tablet
Campaign
Connect people to information: when they need it most

We can help you connect, manage, validate and optimize production.

Learn More
The Connected Mine: A Strategy for Success
Businessman standing outside of a glass building
Blog
The Connected Mine: A Strategy for Success

See digital initiatives through to the end in your mines with six simple but powerful steps.

Read Now
InnovationSuite Analytics & IIOT Software
Two employees in the factory viewing a tablet in front of a Rockwell Automation product
Software
InnovationSuite Analytics & IIOT Software

InnovationSuite brings together FactoryTalk Analytics and MES with PTC ThingWorx and AR technologies. This makes it easy for you to connect and improve operational insight.

Get Started
  1. Chevron LeftChevron Left United Kingdom Chevron RightChevron Right
  2. Chevron LeftChevron Left Company Chevron RightChevron Right
  3. Chevron LeftChevron Left News Chevron RightChevron Right
  4. Chevron LeftChevron Left Case Studies Chevron RightChevron Right
Company
About Us Accessibility Careers Diversity, Ethics and Integrity Engage Online Community Investor Relations Modern Slavery Statement Sustainability Trust Center
 
News & Events
Newsroom Press Releases Automation Fair Upcoming Events
 
Trending Topics
Cybersecurity Digital Transformation Smart Manufacturing The Connected Enterprise®
 
Training
Webinars Workforce Development Training
 
PartnerNetwork
Find a Partner What is the PartnerNetwork?
 
Our Brands
Allen-Bradley FactoryTalk LifecycleIQ Services
Contact Us
TechConnect Support Customer Care General Inquiries How to Buy Report Ethical Concerns
Insights
ROKStudios Management Perspectives Results Achieved Case Studies Blogs Automation Today Podcasts
BlogRockwell Automation's Blog
SE | EN
Legal Notices
Privacy & Cookies Policy
Email Preferences
Cookie Settings
Accessibility Settings
© 2025 Rockwell Automation
United Kingdom
Please update your cookie preferences to continue.
This feature requires cookies to enhance your experience. Please update your preferences to allow for these cookies:
  • Social Media Cookies
  • Functional Cookies
  • Performance Cookies
  • Marketing Cookies
  • All Cookies
You can update your preferences at any time. For more information please see our Privacy Policy
CloseClose