From Data to Actionable Knowledge: Ford’s Digital Playbook for Efficiency

#SmartManufacturing #DigitalTransformation #DataToKnowledge #OperationalExcellence #VirtualManufacturing #Industry40

“The real transformation happens when you turn years of manufacturing experience into a digital ‘book of knowledge’- standardized, validated, and applied consistently across programs.” - Mr. Anandanatarajan Venkatraman, Director- Powertrain Manufacturing Engineering, International Markets Group, Ford

November 2025 : As manufacturers strive to translate data into measurable operational gains, standardization, digitization, and virtual collaboration are proving to be powerful enablers. Mr. Anandanatarajan Venkatraman, Director - Powertrain Manufacturing Engineering, International Markets Group, Ford, shared how Ford has systematically transformed years of manufacturing experience into a digitally enabled “book of knowledge” that drives efficiency and innovation across its global operations.

“This has been a saga for years for OEMs and Tier suppliers alike,” he remarked. Ford’s approach begins with codifying lessons learned across every function vehicle launches, powertrain programs, battery production into Bills of Process and Bills of Design. This extensive “book of knowledge” is then digitally tested and validated before being applied to new programs.

By embedding these standards early in the process design phase, Ford reduces complexity while maintaining high sophistication. “It’s about innovating with purpose,” Mr. Anandanatarajan explained. “Not too much complication, but bringing sophistication in a simple way.”

He illustrated this with a powerful example from the pandemic era. During peak COVID, Ford had to integrate a new I4/I5 engine program into a V6 line in South Africa without any travel. Leveraging virtual manufacturing capabilities and their digital knowledge base, the team in India comprising over 12,000 employees across finance, engineering, and manufacturing functions was able to plan and execute the project remotely.

“When we landed just one week before implementation, the line was ready. Implementation time was reduced by two months,” he said. “It was not only a cost enabler but also a quality enabler.”

This virtual-first, data-to-knowledge approach has delivered tangible results across Ford’s safety, quality, delivery, cost, people, and morale (SQDCM) metrics. By digitizing standards and applying them consistently, Ford accelerates execution timelines, minimizes risk, and improves operational performance globally.

For Mr. Anandanatarajan, the lesson is clear: collecting data is not enough. The real transformation happens when organizations institutionalize knowledge, digitally validate it, and apply it consistently to complex programs, regardless of physical location.

Mr. Anandanatarajan shared these insights as a panelist during the 3rd Edition of the ACMA Automotive Smart Manufacturing Think Turf, powered by Pro MFG Media, in a discussion on “Advanced Factory Management and Optimization.”

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