Manufacturing Analytics ROI — Gunung Raja Paksi (GRP)

At GRP, Indonesia’s largest private steelmaker, I spearheaded an enterprise-wide analytics and Industry 4.0 transformation — integrating ERP + plant data, predictive procurement, and executive dashboards to deliver measurable ROI and modernize legacy workflows.

My Contributions

  • ERP & Plant Data Integration: Unified fragmented ERP, plant historians, vendor feeds, and price indices into a governed data backbone with audit trails and lineage.
  • Predictive Procurement: Developed ML models to forecast scrap/raw material price movements, enabling buyers to time purchases optimally and reduce cost volatility.
  • Executive Dashboards: Delivered semantic BI models (Power BI / QuickSight) with standardized KPIs across procurement, production, and finance; implemented row-level security (RLS).
  • Industry 4.0 Transformation: Re-engineered legacy procurement and production workflows into automated, IoT- and data-driven processes. Introduced predictive maintenance, real-time monitoring, and digital twins to shift GRP’s operating model from reactive to proactive.
  • Governance & Change Management: Established KPI governance, standardized reporting hierarchies, and trained buyers, operations staff, and finance leaders — moving the org from static reports to weekly executive reviews.

Context

Volatile scrap/raw material prices, siloed ERP vs. plant data, and manual reporting slowed decisions and increased procurement costs. Legacy workflows lacked predictive insight or automation.

Mission

Establish a governed analytics & Industry 4.0 foundation — integrating ERP + plant data, enabling predictive procurement, automating workflows, and providing trusted KPIs through executive dashboards.

Architecture Overview

ERP + plant historian + vendor feeds → curated data warehouse → feature store for procurement → predictive ML models → Industry 4.0 workflows → governed BI dashboards.

GRP analytics and Industry 4.0 architecture
Integrated ERP + plant + external feeds → predictive models + Industry 4.0 automation → governed BI dashboards

Executive & Operations Dashboards

Role-based dashboards for procurement, operations, and finance — enabling a shift from reactive to predictive, and aligning all functions on governed KPIs.

Procurement overview
Spend analysis, supplier performance, and buy-window recommendations
Price forecast
Forecasted scrap/raw material prices with confidence intervals
Operations KPI
Production throughput, quality, and utilization trends
Finance KPI
Working capital, cost-to-serve, and budget variance tracking

Results

  • Procurement ROI: Optimized material purchase timing, reducing volatility and emergency buys.
  • Operational Efficiency: Weekly decision cadence established around trusted KPIs.
  • Industry 4.0 Adoption: Legacy manual flows upgraded into digital, automated, and predictive workflows, positioning GRP as a modern, competitive steelmaker in Southeast Asia.
  • Executive Alignment: Dashboards and predictive insights became central to C-suite strategy.

Tech Stack

Python • SQL • Power BI / QuickSight • Airflow • ERP Connectors • Cloud Data Warehouse • GitHub Actions • Terraform (IaC) • IoT / Industry 4.0 Integrations

Explore how Industry 4.0 workflows can modernize your operations →