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Factories of the Future Find Growth and Sustainability Through Digitalization

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Factories of the Future Find Growth and Sustainability Through Digitalization
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The World Economic Forum announced today the addition of 15 new sites to its Global Lighthouse Network, a community of world-leading manufacturers using Fourth Industrial Revolution technologies to enable bottom-line growth. Despite the COVID-19 pandemic’s unprecedented disruption, 93% achieved an increase in product output and found new revenue streams.

Notably, these leading innovators created new revenue streams while driving environmental sustainability – 53% are seeing measurable and marked environmental sustainability benefits. Some have seen almost a total reduction in CO2 emissions, double-digit increases in efficiency and reduction in material use. The new report, Reimagining Operations for Growth, outlines how manufacturers accomplished these results. Their CEOs will provide more insights at the Lighthouses Live event, featuring keynote speaker Satya Nadella, CEO of Microsoft and Alex Gorsky, chairman and CEO of Johnson & Johnson on 17 March at 14.00 CET. See below for a full list of the new Lighthouses and their achievements.

The Lighthouse Network and its 69 sites are a platform to develop, replicate and scale innovations, creating opportunities for cross-company learning and collaboration, while setting new benchmarks for the global manufacturing community.

While 74% of companies remained stuck in pilot purgatory in 2020, research based on learnings from the network reveals that scalable Fourth Industrial Revolution technologies are key to long-term growth. By fully embracing agile ways of working, these manufacturers have been able to respond to disruption and ongoing shifts in supply and demand along their production network and value chains. They also prioritized workforce development – reskilling and upskilling employees for advanced manufacturing jobs – at the same pace and scale.

The new Lighthouses:

Asia

Bosch (Suzhou, China):As a role model of manufacturing excellence within the group, Bosch Suzhou deployed a digital transformation strategy in manufacturing and logistics, reducing manufacturing costs by 15% while improving quality by 10%.

Foxconn (Chengdu, China): Confronted with fast-growing demand and labour skill scarcity, Foxconn Chengdu adopted mixed reality, artificial intelligence (AI) and internet of things (IoT) technologies to increase labour efficiency by 200% and improve overall equipment effectiveness by 17%.

HP Inc. (Singapore): Facing an increase in product complexity and labour shortages leading to quality and cost challenges, along with a move at the country level to focus on higher-value manufacturing, HP Singapore embarked on its Fourth Industrial Revolution journey to transform its factory from being manual, labour intensive and reactive to being highly digitized, automated and driven by AI, improving its manufacturing costs by 20%, and its productivity and quality by 70%.

Midea (Shunde, China): To expand its e-commerce presence and overseas market share, Midea invested in digital procurement, flexible automation, digital quality, smart logistics and digital sales to improve product cost by 6%, order lead times by 56% and CO2 emissions by 9.6%.

ReNew Power (Hubli, India): Facing exponential asset growth and rising competitiveness from new entrants, ReNew Power, India’s largest renewables company, developed Fourth Industrial Revolution technologies, such as proprietary advanced analytics and machine learning solutions, to increase the yield of its wind and solar assets by 2.2%, reduce downtime by 31% without incurring any additional capital expenditure, and improve employee productivity by 31%.

Tata Steel (Jamshedpur, India): Facing operational KPI stagnation and an impending loss of captive raw material advantage, Tata Steel Jamshedpur’s 110-year-old plant with deeply rooted cultural and technology legacies deployed multiple Fourth Industrial Revolution technologies, such as machine learning and advanced analytics in procurement to save 4% on raw material costs, and prescriptive analytics in production and logistics planning to reduce the cost of serving customers by 21%.

Tsingtao Brewery (Qingdao, China): Facing growing consumer expectations for personalized, differentiated and diverse beers, Tsingtao Brewery rethought its use of smart digital technologies along its value chain to enable its 118-year-old factory to meet consumer needs, reducing customized order and new product development lead times by 50%. As a result, it increased its share of customized beers to 33% and revenue by 14%.

Wistron (Kunshan, China): In response to high-mix and low-volume business challenges, Wistron leveraged AI, IoT and flexible automation technologies to improve labour, asset and energy productivity, not only in production and logistics but also in supplier management, improving manufacturing costs by 26% while reducing energy consumption by 49%.

Europe

Henkel (Montornès, Spain): To drive further improvements in productivity and boost the company’s sustainability, Henkel built on its digital backbone to scale Fourth Industrial Revolution technologies linking its cyber and physical systems across the Montornès plant, reducing costs by 15% and accelerating its time to market by 30% while improving its carbon footprint by 10%.

Johnson & Johnson Consumer Health (Helsingborg, Sweden): In a highly regulated healthcare and fast-moving consumer goods environment, J&J Consumer Health addressed customer needs through increased agility using digital twins, robotics and high-tech tracking and tracing to enable 7% product volume growth, with 25% accelerated time to market and 20% cost of goods sold reduction. It made further investments in connecting green tech through Fourth Industrial Revolution technologies to become Johnson & Johnson’s first ever CO2-neutral facility.

Procter & Gamble (Amiens, France): P&G Amiens, a plant with a steady history of transforming operations to manufacture new products, embraced Fourth Industrial Revolution technologies to accommodate a consistent volume increase of 30% over three years through digital twin technology as well as digital operations management and warehouse optimization. This led to 6% lower inventory levels, a 10% improvement in overall equipment effectiveness and a 40% reduction in scrap waste.

Siemens (Amberg, Germany): To achieve its productivity goals, this site implemented a structured lean digital factory approach, deploying smart robotics, AI-powered process controls and predictive maintenance algorithms to achieve 140% factory output at double product complexity without an increase in electricity or a change in resources.

Middle East

STAR Refinery (Izmir, Turkey): To maintain a competitive edge within the European refinery industry, Izmir STAR Refinery was designed and built to be “the technologically most advanced refinery in the world”. Leveraging more than $70 million investments in advanced technologies (e.g., asset digital performance management, digital twin, machine learning) and organizational capabilities, STAR was able to increase diesel and jet yield by 10% while reducing maintenance costs by 20%.

North America

Ericsson (Lewisville, USA):Faced with increasing demand for 5G radios, Ericsson built a US-based, 5G-enabled digital native factory to stay close to its customers. Leveraging agile ways of working and a robust IIoT architecture, the team was able to deploy 25 use cases in 12 months. As a result, it increased output per employee by 120%, reduced lead time by 75% and reduced inventory by 50%.

Procter & Gamble (Lima, USA): A shift in consumer trends meant more complex packaging and an increased number of products that had to be outsourced. To reverse the tide, P&G Lima invested in supply chain flexibility, leveraging digital twins, advanced analytics and robotic automation. This resulted in an acceleration of speed to market for new products by a factor of 10, an increase in labour productivity by 5% year on year, and plant performance that was two times better than competitors in avoiding stock-outs during the year.

“This is a time of unparalleled industry transformation. The future belongs to those companies willing to embrace disruption and capture new opportunities. Today’s disruptions, despite their challenges, are a powerful invitation to re-envision growth. The lighthouses are illuminating the future of manufacturing and the future of the industry,” said Francisco Betti, Head of Shaping the Future of Advanced Manufacturing and Production, World Economic Forum.

Enno de Boer, Partner, McKinsey & Company, and Global Lead, Manufacturing, said: “The 69 Lighthouse manufacturers open a window into the future of operations. Though no industry is immune from digital transformation, four sectors are resetting benchmarks – Advanced Industries, Consumer Packaged Goods, Pharmaceutical and Medical products, and Heavy Industries. We are seeing a paradigm shift emerge, from reducing cost to more focus on enabling growth and environmental sustainability. The Lighthouses are proving that unlocking smart capacity through digital technologies is more effective than spending on capital infrastructure.”

The goal of the Global Lighthouse Network is to share and learn from best practices, support new partnerships and help other manufacturers deploy technology, adopt sustainable solutions and transform their workforces at pace and scale. The extended network of “Manufacturing Lighthouses” will be officially recognized at Lighthouse Live: Reimagining Operations for Growth at 14.00 CET/09.00 EST 17 March.

Together with a diverse group of experts and innovators, the meeting aims to initiate, accelerate and scale-up entrepreneurial solutions to tackle climate change and advance sustainable development.

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7 Trends Reshaping a USD 3.9 Trillion Global Halal Industry

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The Global Halal Market (GHM) is not just growing, it’s exploding. Driven by a surging Muslim population, rising disposable incomes, and shifting consumer preferences, this behemoth is projected to reach a staggering USD 3.9 trillion by 2027. But what’s driving this explosive growth? Buckle up, because 2024 promises a thrilling ride fueled by cutting-edge technology, ethical consumerism, and personalized convenience. Here’s your deep dive into the 7 hottest trends reshaping the global halal landscape:

Halal Tech Revolution: Where Silicon Valley Meets Mecca

Forget clunky processes and opaque sourcing. The halal industry is getting a tech makeover, and it’s about time. Blockchain is ensuring ethical sourcing and transparent supply chains, from farm to fork. Imagine halal meat traced back to its free-range roots, with every step documented on a tamper-proof digital ledger. Artificial intelligence is optimizing slaughterhouses, automating processes, and ensuring humane treatment of animals. Halal e-commerce platforms are booming, bringing convenience and halal-certified products to Muslim consumers worldwide. Think Amazon, but with prayer apps, virtual tours of halal farms, and even halal-compliant fintech solutions – the future of halal is digital and delicious!

Ethical Halal: Beyond Compliance, Embracing Values

Muslim consumers are no longer satisfied with just a halal label. They crave sustainability, animal welfare, and organic goodness. Expect a surge in plant-based halal options, from juicy burgers to creamy milkshakes made with innovative pea protein and lentil blends. Ethically sourced meat, raised on antibiotic-free feed and roaming in spacious pastures, will be the new gold standard. And get ready for a beauty revolution: cruelty-free cosmetics and hygiene products that adhere to Islamic principles will pamper consumers with peace of mind.

Convenience is King: Busy Lives, Halal Solutions

In today’s fast-paced world, convenience reigns supreme. The halal industry is taking note, with solutions tailor-made for busy Muslim lives. Subscription meal kits will deliver pre-portioned, halal-certified ingredients straight to doorsteps, complete with recipe cards for stress-free meal prep. Halal food delivery apps will take the guesswork out of dining out, connecting users with a curated selection of restaurants and cafes offering delicious and compliant meals. And for those special occasions, on-demand halal catering will ensure stress-free gatherings, leaving hosts free to enjoy the festivities.

Beyond Food: The Halal Universe Expands

The halal industry is shedding its “food-only” label and branching out into exciting new frontiers. Halal travel is booming, with destinations vying for Muslim tourists by offering halal amenities, prayer spaces, and culturally sensitive experiences. Imagine exploring Marrakech’s vibrant souks or unwinding on a pristine Maldives beach, all while knowing your needs are catered to. Halal cosmetics are gaining traction, with innovative brands formulating products free of alcohol, animal derivatives, and harsh chemicals. And even the pharmaceutical industry is taking notice, developing halal-compliant medications and healthcare products that align with Islamic principles.

Science & Innovation: Reimagining Halal with Cutting-Edge Tech

Research labs are not just churning out papers; they’re cooking up a futuristic halal feast. Lab-grown halal meat is no longer science fiction, with companies like Eat Just and Aleph Farms creating meat indistinguishable from its conventional counterpart, but without the ethical and environmental concerns. Plant-based alternatives are evolving beyond bland tofu, with innovative textures and flavors mimicking everything from juicy steaks to succulent lamb shanks. Get ready for halal food reimagined with cutting-edge technology, offering delicious and sustainable options for the future.

Health & Wellness: Halal Goes Holistic

Muslim consumers are prioritizing their well-being like never before. Enter functional halal foods infused with ingredients like probiotics, antioxidants, and adaptogens, designed to nourish the body and mind. Sports nutrition is another burgeoning market, with protein powders and energy bars formulated specifically for Muslim athletes seeking halal-compliant performance boosters. And for those managing chronic conditions, dietary supplements tailored to diabetes management, weight loss, or heart health will offer halal solutions for holistic well-being.

Storytelling & Branding: Building Trust, Shaping Perceptions

In a crowded marketplace, differentiating your brand is key. The halal industry is catching on, embracing compelling narratives and values-driven branding. Showcase your commitment to ethical sourcing, sustainability, and community engagement. Share inspiring stories of the farmers who raise your halal meat, the scientists developing innovative food technologies, or the communities you empower through your business practices. By building trust and aligning with consumer values, halal brands can stand out.

Embrace the Halal Revolution:2024 is not just a year on the calendar; it’s the dawn of a new era for the halal industry. By harnessing the power of technology, embracing ethical values, and catering to evolving consumer needs, halal businesses can tap into a USD 3.9 trillion market brimming with potential. So, whether you’re a food producer, travel blogger, or tech whiz, join the halal revolution. Optimize your offerings, tell your story, and connect with Muslim consumers worldwide. The future of halal is bright, and the time to act is now.


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Beyond Andalusia: Exploring Spain’s Islamic Heritage through Halal Tourism

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Spain’s evolving landscape of Muslim-friendly tourism is a testament to its rich Islamic history and its commitment to embracing diverse cultural needs. As we head into 2023, projections indicate a staggering 85 million international visitors to Spain, a 16.4% increase from the previous year, highlighting the country’s growing appeal as a global tourist destination. A significant portion of these tourists are from Muslim-majority countries, drawn to Spain’s Islamic heritage and the burgeoning availability of Halal services and tailored cultural experiences.

The Rise of Halal Tourism in Spain

Spain’s shift towards accommodating Muslim tourists is evident in the increasing number of Halal-certified establishments and services. The Spanish Halal Institute has reported a surge in businesses seeking Halal certification, a rise from 100 in 2010 to over 500 in recent years. This growth is not only a response to the rising Muslim visitor numbers but also a strategic move by Spanish businesses to tap into the lucrative Muslim market.

Muslim-friendly Services Across Spain

Beyond the traditionally popular Andalucía, other regions in Spain are adapting to the needs of Muslim tourists. Cities like Barcelona, Toledo, and Madrid now offer a range of Halal dining options, prayer facilities, and culturally sensitive services. For instance, the Mandarin Oriental in Barcelona, a Halal-certified hotel, offers amenities tailored to Muslim guests, including prayer mats and Halal food options. Similarly, the Costa del Sol Hotel in Torremolinos has trained its staff in Muslim culture and traditions, enhancing the experience for its Muslim clientele.

Cultural and Historical Tourism

Spain’s Islamic history, particularly the legacy of Al-Andalus, is a major draw for Muslim visitors. Educational initiatives like walking tours in Toledo, led by Aicha Fernández, and Madrid’s Muslim and Arab heritage tours, organized by Rafael Martínez, provide insights into Spain’s rich Islamic past. These tours are not just tourist attractions but educational experiences, offering deep dives into the historical and cultural significance of Spain’s Islamic era.

Economic Impact and Market Potential

The economic potential of Muslim-friendly tourism in Spain is immense. According to a report by the State of the Islamic Economy (2022), the global Muslim population, a significant portion of which belongs to the rising middle class, is increasingly travel-savvy and demands tailored services. This presents a lucrative opportunity for Spanish businesses in the tourism sector.

Government Initiatives and Recognition

The Spanish government’s role in promoting Muslim-friendly tourism is pivotal. Efforts like the creation of Halal tourism guides by municipalities like Málaga, which won recognition at the Halal In Travel Global Summit in Singapore, underscore the national commitment to positioning Spain as a Muslim-friendly destination.

Challenges and Opportunities

Despite the progress, challenges remain. Celia Rodríguez, a Spanish revert, notes the scarcity of Halal options in some regions and the need for better-informed services for Muslim tourists. This gap presents an opportunity for businesses to further tailor their offerings and improve communication with Muslim clients.

Global Context and Future Prospects

Globally, the trend towards Muslim-friendly tourism is gaining momentum, with countries like South Korea and Japan also emerging as popular destinations. Spain’s strategic approach to embracing and catering to the needs of Muslim tourists not only enhances its competitive edge in the global tourism market but also promotes cultural understanding and inclusivity.


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TB Research Shows a Good Diet can cut Infections by Nearly 50%

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Tuberculosis is the single most deadly infectious killer of humankind. It claimed 1.6 million lives in 2021 alone. As the search for effective ways to fight the disease continues, the findings of new research offer hope: a good diet can cut infections by nearly 50%. Yogan Pillay and Madhukar Pai write that nutrition is a vaccine in all but name.

For centuries, we have known that tuberculosis is a social disease. It thrives on poverty and social factors such as malnutrition, poor housing, overcrowding, unsafe work environments and stigma. Globally in 2021 an estimated 2.2 million cases of TB were attributable to undernourishment, 0.86 million to HIV infection, 0.74 million to alcohol use disorders, 0.69 million to smoking and 0.37 million to diabetes.

But knowledge about social determinants alone does not always translate into tangible action and progress. A new trial in India, called RATIONS, aimed to determine the effect of nutritional supplementation on new cases of tuberculosis in households of adults with pulmonary TB. The research found that providing food baskets to people with TB and their households could go a long way to prevent and mitigate the disease.

No easy silver bullets

The TB community has typically looked for biomedical solutions, or “silver bullets”, for a social pathology, and we are struggling to make progress. Since the COVID pandemic, TB mortality and incidence have increased globally, putting TB back on top as the single most deadly infectious killer of humankind.  In 2021, 1.6 million people died of TB. In Africa, TB incidence is high (212 per 100,000 population) with a high case fatality rate because of the HIV epidemic.

Undernutrition is the most important cause of TB. This has been shown in studies in many countries, including South Africa, where researchers found poor levels of nutrition in patients admitted to a specialized TB hospital. Malnutrition refers to all forms of deficiencies in nutrition, including over-nutrition and obesity. Undernutrition refers more specifically to a deficiency of nutrients. While we know that many patients with TB have poor nutrition, the latest evidence is that undernutrition also plays a key role in TB within households.

The results of the Reducing Activation of Tuberculosis by Improvement of Nutritional Status (RATIONS) trial show that improved nutrition in family members of patients with lung TB reduced all forms of TB by nearly 40%, and infectious TB by nearly 50%.

This trial recruited 10,345 household members of 2,800 patients with lung TB.

  • All TB patients received a monthly 10kg food basket (rice, pulses, milk powder, oil) and multivitamins for six months.
  • In one group family members received 5kg rice and 1.5kg pulses per person per month, while the other group of family members did not get food baskets.

Food worked like a vaccine in this trial, cutting the risk of household members developing TB.  Nutrition could also protect against other conditions such as anaemia, diarrhoea and respiratory infections, but these were not not the main focus of the trial. An accompanying paper, based on the results of the RATIONS trial, showed that severe undernutrition was present in nearly half of all patients.

An early weight gain in the first two months was associated with 60% lower risk of TB mortality. The other benefits were higher treatment success and better weight gain. During the six-month follow-up period, a remarkable treatment success rate of 94% was achieved.

Getting food to patients

How expensive was the intervention? The cost of a food basket was US$13 per TB patient per month and US$4 per household member per month and could be delivered, even in rural areas, using field staff. Even before the RATIONS trial, the Indian government had recognised the need for nutrition support for people with TB, and in 2018 launched “Nikshay Poshan Yojana”, a direct benefit transfer scheme. Under this scheme, each TB patient receives a financial incentive of US$6 per month for the duration of the anti-TB treatment (typically, six months for people with drug-sensitive TB).

Emerging data suggests that while the scheme improves the treatment completion rates among patients with TB in India, they often receive their payments late. There is a need to improve the efficiency and provide timely payments.

The new RATIONS trial suggests that directly providing food baskets may be another effective strategy.

Many countries, including India, have other social security programmes, including public distribution systems  to provide food grains at subsidised prices. Using existing channels to provide extra food rations to people with TB, and expanding the menu to include proteins such as pulses and millets, is a strategy worth exploring. This could also have positive effects on other diseases such as diabetes.

Implications for South Africa

South Africa is one of the countries labelled by the World Health Organization as a “high TB burden country”.

What does this latest research mean for South Africa? Statistics South Africa reported that in 2021 2.6 million people had inadequate access to food and a further 1.1 million stated they had “severe” inadequate access to food. More than 683,000 children five years and younger experienced hunger.

This toxic mix requires prevention of TB by nutritional support, drugs to prevent TB infections and early diagnosis with molecular tests and treatment.

With high levels of food insecurity and undernutrition in South Africa, fuelled by the highest levels of inequality, it is critical that South Africa includes social benefits for people with TB and those in their households to reduce the prevalence of TB in the country and to meet the Sustainable Development Goals for 2030.

Regardless of how social benefits are distributed, action must be based on evidence. We need better tests, cures and vaccines for TB, but they alone cannot end the epidemic.  TB patients must be provided with the social benefits that they need and deserve, as a basic human right.

Courtesy: The Conversation


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