The World Economic Forum (WEF) has declared Hindustan Unilever Limited’s (HUL) Doom Dooma factory in Assam as an Advanced Fourth Industrial Revolution (4IR) End-to-End Value Chain Lighthouse. This prestigious recognition underscores the factory’s exemplary use of advanced technologies such as artificial intelligence (AI), automation, cloud computing, and the Internet of Things (IoT).
By achieving this distinction, HUL becomes the only FMCG company in India to have three factories honored as Advanced 4IR Lighthouses.
A Hat-Trick of Achievements for HUL
The Doom Dooma site joins HUL’s Dapada factory, recognized in 2022, and the Sonepat factory, recognized in 2023. This recognition places HUL at the forefront of innovation and sustainability in the FMCG sector. The WEF’s Global Lighthouse Network, established in 2018, identifies manufacturing sites that excel in deploying 4IR technologies to transform operations and enhance efficiency.
Cutting-Edge Technologies Transform Operations
At the Doom Dooma factory, over 50 digital initiatives have been implemented to optimize the end-to-end supply chain. These technological innovations have significantly boosted productivity, improved product quality, and reduced waste.
Enhancing E-Commerce with AI-Powered Vision
The factory uses an AI-powered vision system to streamline operations and enable rapid changeovers between product lines. This system has reduced changeover times by an impressive 85%, enabling faster delivery of products to meet e-commerce demands.
Generative AI for Better Product Quality
HUL employs generative AI-enabled consumer insights to improve product quality with remarkable speed and accuracy. With 97% precision, the factory analyzes consumer feedback, driving swift operational optimizations to ensure product superiority.
Real-Time Demand Planning
An AI-enabled digital planning system dynamically analyzes over 10,000 product combinations to meet real-time demand. By reducing the frozen planning period from 14 days to one day, the system has enhanced product availability by 92%.
Sustainability as a Core Focus
The factory also champions sustainable practices, leveraging technology to minimize its environmental footprint.
Digital Twin for Sustainable Packaging
A Digital Twin system enables the creation of a virtual replica of the factory’s machines. This innovation allows simulations and testing of operations virtually, leading to a 60% reduction in laminate plastic waste and a 21% reduction in virgin plastic usage.
Enhanced Labor Productivity
By integrating an in-house AI-powered workforce allocation tool, the factory has boosted labor productivity by 400%. The tool matches staff to high-priority tasks based on their skills and provides targeted training to address gaps.
A Significant Milestone for HUL and the Region
HUL’s Doom Dooma factory, located in Tinsukia, Assam, stands as India’s largest Beauty & Wellbeing manufacturing unit. With an annual production capacity exceeding 5.4 billion units and a workforce of 675 employees, the factory plays a pivotal role in India’s FMCG landscape. It produces over 130 SKUs of beauty products under renowned brands like Glow & Lovely, Pond’s, Vaseline, Sunsilk, Clinic Plus, TRESemmé, and Dove.
This milestone demonstrates HUL’s commitment to innovation, sustainability, and workforce development, showcasing how cutting-edge technology can coexist with environmental and social responsibility.
Leaders Applaud the Achievement
HUL’s leadership has expressed immense pride in this recognition. Rohit Jawa, CEO and MD of HUL, stated, “By integrating advanced technologies, we have revolutionized our operations and significantly enhanced productivity and product quality. Such initiatives not only drive our business but also contribute to a better future.”
Yogesh Mishra, Executive Director of Supply Chain at HUL, added, “This recognition highlights our relentless pursuit of innovation and underscores our commitment to leveraging technology for efficiency, sustainability, and growth.”
Setting New Benchmarks for the Industry
The Doom Dooma factory’s recognition as an End-to-End Value Chain Lighthouse. Underscores the growing role of AI and digitization in manufacturing. As part of the WEF’s Global Lighthouse Network. The site exemplifies how 4IR technologies can transform traditional operations into sustainable, efficient, and consumer-focused systems.
With its focus on innovation, HUL continues to set benchmarks for the FMCG industry. By aligning its operations with global sustainability goals. The company demonstrates how businesses can lead the way in building a future-ready supply chain.
