Haridwar, IN - Lighthouse award in Supply-Chain and Resilience

Haridwar is Hindustan Unilever's largest manufacturing hub, designed for stable, high-volume runs. As e-commerce grew at roughly 35% a year, the site had to absorb a 1.5x rise in active SKUs and four times the demand volatility, much of it from small, freshness-critical orders that its format-rigid lines and weekly fixed planning could not serve. Inventory ran high, freshness suffered, and the e-commerce service level had slipped to 66%. The plant rebuilt its value chain around an Industry 4.0 ecosystem that connects suppliers, production, logistics and customers into one self-adapting system: machine-learning rapid planning, agentic AI sourcing, a magnetic-levitation format-agnostic line and an ML logistics control tower. The result was changeovers cut by about 40%, end-to-end supply chain response time down 72%, minimum order quantities reduced 40% and overall service levels lifted to about 99.6%.

Sonepat, IN - Lighthouse award in Sustainability

Sonepat is the company's largest malt-based nutrition site, sitting in an agrarian belt where more than 30% of the surrounding district shows severe groundwater depletion and where energy use was carbon-intensive. As volume grew 35%, resource scarcity became a direct threat to production continuity: a switch to regeneratively-sourced grain introduced raw-material variability and lifted waste, while seasonal swings destabilised both boiler and chiller operations and complicated the elimination of Scope 1 and 2 emissions. The site moved from siloed, on-premise data collection and fixed-logic control to a cloud data platform integrating its ERP with closed-loop, AI-enabled process control across mixing, cleaning, cooling, steam-raising and inbound logistics. The result was a 99% cut in Scope 1 and 2 emissions, a 37% reduction in inbound Scope 3 emissions, roughly 29% lower energy intensity, and aquifer recharge at about 100 times site consumption, all delivered alongside the 35% production increase.

Hefei, CN - Lighthouse award in Supply-Chain and Resilience

Driven by booming e-commerce in consumer goods, the site deployed flexible automation, digital and AI use cases across delivery, warehousing, production and end-to-end performance management to lift agility and quality for demanding customers. Site conversion cost fell 34% over three years.