The ROCA Group, founded in 1917 in Barcelona, is a global leader in bathroom solutions with 80 factories and 21,000+ employees.
Committed to industrial and operational excellence, ROCA aimed to enhance operational efficiency through digital transformation, piloting a new approach at two sites. Its teams needed accurate, reliable, and standardized measurement of manufacturing KPIs to support decision-making. With solutions from AVEVA and Schneider Electric, ROCA linked production and energy data, boosting operational efficiency and setting the stage for global rollout.
" We need trusted and accurate data and information, especially for OEE and quality yields. Our AVEVA solution provides us with real-time data to make the right decisions and focus on the priority actions to drive our operational excellence.
We saw an increase in OEE of more than 2% in the first few months and expect it to reach 5%. "
—Miguel Barahona, Industrial Manufacturing and Engineering Director, ROCA Group
Challenges
- Limited visibility into process data and inefficient tools for process optimization caused delays in troubleshooting and made it difficult to identify system constraints
- Increased volume and complexity of process data
- Difficulty connecting energy data to production activities
- Needed accurate and reliable performance metrics to optimize KPIs and resource allocation
Solutions
- Deployed AVEVA™ PI System™, AVEVA™ Manufacturing Execution System, and AVEVA™ System Platform to collect data from production line operations for real-time visibility and integration with ROCA’s ERP System. ROCA also used EcoStruxure™ Power Monitoring Expert from Schneider Electric to track energy usage. The centralized and connected energy consumption and production data delivered actionable insights across the piloted factory sites.
Results
- Improved data accuracy, reduced manual errors, and gained real-time insights into production and energy use
- Streamlined processes and increased operational efficiency
- Stronger cross-functional collaboration and decision-making
- Established templates, KPIs, and governance frameworks to ensure consistency and scalability
- Improved OEE by 2%, and is expected to increase to 5% by the end of the first year
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