Unilever is partnering with Accenture to scale its use of AI-enabled digital twins. This massive expansion covers Unilever’s global manufacturing network. Consequently, the next-generation technology will help factories improve product quality. It will also boost overall efficiency and help teams respond faster to consumer demand.
Virtual models create identical digital copies of physical factory equipment and production lines. Furthermore, they use live data from the shop floor. This process helps teams monitor and predict how physical machines perform. Therefore, Unilever plans to build more than 40 new digital twins over the next 18 months.
“Scaling AI across our operations isn’t just a technological shift; it’s a commitment to superior products, sustainability, and empowering our teams across our factories. Through our partnership with Accenture to accelerate digital twins, we are turning innovation into measurable impact to create desirable brands for our 3.7 billion consumers worldwide,” said Adam Raeburn-James, Global VP for Digital Business Operations, Unilever.
Real Impact Across Global Factories
The company already sees massive benefits from these advanced digital tools. For example, a factory in Raeford, North Carolina, makes Dove, Degree, and Axe deodorants. Its digital twin predicts 95% of process flow restrictions. Because of this tracking, the site achieved a 20% waste reduction. The facility also saw a 10% uplift in production capacity.
Meanwhile, a site in Haldia, India, uses an energy twin for Surf and Sunlight detergents. The system optimizes fan speeds and temperatures. As a result, the factory reduced thermal energy consumption over two years.
In Poznan, Poland, another twin stabilizes viscosity variation in Knorr and Hellmann’s mayonnaise. This solution cuts minor stoppages by up to 20%. Additionally, it reduces waste by nearly 30%.
At the Gandhidham plant in India, real-time recommendations reduced Dove soap defects by 30% over four years. Finally, a plant in Cu Chi, Vietnam, optimizes raw materials dosing for OMO laundry detergent. This intelligent mixer saves 1-2% in premium ingredients.
“Unilever has long been recognized for its supply chain excellence, and expanding the use of manufacturing digital twins reflects the company’s continued focus on both technology and people. Having invested early in AI, the company is setting the standard for pairing advanced tools with smart process design and disciplined execution on the shop floor. Together, we’re setting the benchmark for how industrial AI creates long-lasting value in the consumer goods sector,” said Nicole van Det, CEO Accenture Netherlands and Nordics and global account lead for Unilever.
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News Source: Businesswire.com
