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Inside The Smart Factory

Build, lead, and achieve manufacturing excellence during the fourth industrial revolution


The ultimate goal for today’s automotive manufacturers is the ‘smart factory’, defined by Deloitte as “a flexible system that can self-optimize performance across a broader network, self-adapt to and learn from new conditions in real or near-real time, and autonomously run entire production processes.”

A smart factory uses AI (artificial intelligence), machine learning and other advanced technologies to improve productivity, profitability and quality, and will be more agile than anything we have previously seen.

Among the key outputs of the smart factory include smarter use of data for faster throughput, improved processes, extended visibility and control, better quality, higher performance and improved profitability — but also to facilitate large-scale manufacturing in a more sustainable way.

Smart factories have the potential to transform operating profit and margin for automotive OEM manufacturers.

Effective deployment of data-driven solutions has already demonstrated that it can cut costs in terms of machine uptime, effectiveness and usage of consumables.



Machine downtime improvement:


Forecasting accuracy:

Up to 80%

Inventory holding decreased:


Maintenance and cost reduction:


Quality improvement:


Increased time to market:



Big data

The opportunity ahead of automakers is to connect everything in an effective, sustainable way. The rewards will be faster throughput, improved processes, extended visibility and control, better quality, higher performance and improved profitability.

While the obstructions preventing the creation of the smart factory are legacy infrastructure and equipment, the biggest challenge may be that of long-established mindset. To get the most out of interconnected factories, production processes, and supply chains, data must be shared with collaborative partners and acted on in the right way - and in real time.

Big data. Boon or big problem? Read our guide and understand the key opportunities for auto makers to capitalize on and make their data meaningful.


Dr Xiaoqin Ma, Head of Technology and Marketing at Onyx InSight

Bryan Rabenau, Castrol innoVentures Territory Leader

Satwik Mehta, Engineering Director, HSSMI

The smart factory needs leadership. The opportunity is there to lead the development of this fourth industrial revolution and reap the rewards.
Robert Hudson, Expert Technologist, Castrol



Inside the smart factory? Sustainable manufacturing

Sustainable manufacturing is going to be the biggest challenge facing automakers in the 21st century because the challenges are no longer just about production and maximizing output. Government and legislative action around the world on pollution, waste and exploitation of resources, and consumer-led environmental campaigns, mean that manufacturers are faced with a range of unprecedented pressures.

It’s possible for manufacturers to use the technologies offered through industry 4.0 to adopt sustainable practices, now, in ways that are commercially, environmentally, and financially beneficial.

Piecing together the Paris dis(agreement). Find out how to make environmental legislation work for you by reading our guide and understanding what the Paris Agreement means for industrial automotive manufacturers.



Satwik Mehta, Engineering Director, HSSMI

Dr Xiaoqin Ma, Head of Technology and Marketing at Onyx InSight

Allan Matthews, Director, International Centre for Advanced Materials (ICAM)

Richard Banks, Global B2B Compliance Leader, BP

By harnessing Industry 4.0, automakers can achieve significant improvements in energy usage and, consequently, in financial and environmental performance.
Michael Capper, Global Development, BP Carbon Neutral



The race for the world championship

As motorsport fans know, the Renault Sport Formula One™ Team choose Castrol Edge to help their car perform on the track. But, behind the scenes, Castrol Hysol SL 45 XBB is also vital in the manufacture of the car’s precision parts too.

Castrol also supplies lubricants to the team’s Enstone technical centre and Renault Sport Racing’s Viry-Châtillon engine operations base.

Today, Renault’s vision is to be the best team in Formula One. It’s a vision that we share at Castrol – and a journey we are very proud to be part of. Watch the video and take a look at our relationship with the Renault Sport Formula One™ Team and the role our products play in helping them achieve the world championship.

We manufacture the components that go into the F1 car, and the machines that create those parts depend on Castrol.
Bob Bell, Chief Technical Officer, Renault Sport Formula One Team



Castrol’s XBB Technology

Castrol’s XBB technology is helping metalworking engineers around the world cut compromise between productivity, performance, safety and cost. Industry-wide, there are initiatives to support greener manufacturing processes and eliminate wastage. The Castrol XBB (no boron or biocide) range of water-based coolants, helps achieve that green objective while safeguarding quality and reducing costs.

Additionally, the Castrol XBB range of metalworking compatible cleaners, once they have reached the end of their useful life as cleaners, can be added to the coolant reservoir and used in machining.

Complementing the XBB fluids are environmentally compliant greases for electrically driven motors, a category that covers extractor fans, pumps, and any machinery that is going to facilitate the mass movement of material, including coolants or components and, for example, long life compressor fluids.

Reduce or eliminate the need for expensive treatment additive top-ups

Exceed system lifetime expectations - without formaldehyde releasing agents or boron

Increase production efficiency, reduce costs and lessen demands on personnel

Extend fluid life and eliminate unnecessary repairs and interventions


The sustainable smart factory.

We help make it happen.