Ajay Kumar Patodia: We are continuously evaluating process upgrades in our Spinning and Knitting divisions

In an era where digitalisation is reshaping manufacturing, companies are increasingly adopting smart technologies to improve efficiency, sustainability, and responsiveness to market demand. Dollar Industries is advancing this transition through integrated digital systems and renewable energy investments. Ajay Kumar Patodia, CFO, Dollar Industries, discusses how smart manufacturing is strengthening the company’s operational agility and long-term competitiveness.

How have smart manufacturing practices (such as automation, digital monitoring, IoT, AI, or data analytics) been integrated into your production processes?

At Dollar Industries, we view digital integration as the backbone of our manufacturing efficiency. A significant milestone in this journey was the successful implementation of SAP S/4HANA in the 2024-25 financial year. We have integrated core modules including Financial Accounting (FI), Sales & Distribution (SD), Materials Management (MM), and Human Resources (HR) along with Production Planning (PP).

This digital overhaul has allowed us to bridge the gap between market demand and our shop floor. By integrating our Spinning and Bleaching units into this centralised digital ecosystem, we have moved away from siloed operations to a unified data environment where production schedules are directly dictated by real-time sales data and analytics.

What measurable benefits have you observed from adopting smart manufacturing—such as improvements in productivity, quality, cost efficiency, energy management, or delivery timelines?

The adoption of the SAP Production Planning module integrated with Sales Data has delivered immediate and measurable benefits:

• Inventory optimisation:We have significantly aligned our manufacturing output with actual market demand. This has prevented over-production, reduced stock-holding costs, and optimised our working capital.
• Energy cost efficiency:Our shift toward smart energy management has been substantial. By installing 95 MW of Wind Power and 8 MW of Solar Power capacity, we have drastically reduced our reliance on conventional power, lowering our operational costs while insulating the company from fluctuating energy prices.
• Process efficiency:The data transparency provided by SAP MM and SD modules ensures raw materials are available exactly when needed, reducing downtime and improving overall plant productivity.

How has smart manufacturing helped your organisation respond to challenges such as labour availability, quality consistency, and sustainability requirements?

Smart manufacturing is central to our sustainability and operational resilience strategy:

• Sustainability & environmental compliance:We have integrated modern environmental technologies into our Bleaching Unit. Our effluent treatment plant now boasts a daily processing capacity of 5 Tonnes, enabling Zero Liquid Discharge (ZLD). This ensures that our growth does not come at the cost of the environment.
• Carbon footprint reduction:Our combined renewable energy portfolio (Wind and Solar) not only powers our plants but actively reduces our carbon footprint, helping us meet global sustainability standards.
• Operational consistency:The SAP system acts as a single source of truth, standardising workflows across departments. This reduces human error in planning and ensures that quality and delivery timelines remain consistent regardless of external fluctuations.

What new technologies or process upgrades are you currently implementing or planning to implement to further enhance smart manufacturing capabilities?

Having established a robust digital core with SAP S/4HANA, our current focus is on Deep Data Analytics. We are leveraging the data generated by the SAP PP and SD modules to further refine our demand forecasting models.

Additionally, we are continuously evaluating process upgrades in our Spinning and Knitting divisions to ensure our machinery interfaces seamlessly with our digital ERP. We aim to further enhance our ZLD capabilities and explore advanced energy monitoring tools to maximise the yield from our Wind and Solar installations.

Looking ahead, how do you see smart manufacturing shaping your company’s growth strategy and competitiveness over the next 3–5 years?

Over the next 3–5 years, smart manufacturing will transition from being an operational tool to a strategic competitive advantage for Dollar Industries.

• Agility:The data-driven culture established by SAP will allow us to react faster to changing fashion trends and consumer preferences than competitors relying on traditional planning.
• Responsible growth:As global markets increasingly Favor sustainable brands, our investments in ZLD and Green Energy (Wind/Solar) position us as a responsible manufacturer, enhancing our brand value and export competitiveness.
• Cost leadership:Continued optimisation of inventory and energy costs via digital and green tech will protect our margins, allowing us to invest in market expansion and R&D.