End-to-end transformation

Designed to break the cycle of pilot projects that never make it to full-scale production, the Omron i-Belt service combines Lean expertise, IT/OT convergence, and end-to-end project responsibility to deliver OEE improvements of over 30%.

Omron is announcing the next stage in the evolution of i-Belt: an end-to-end service for digital Lean transformation aimed at manufacturing companies in Germany, Austria, and Switzerland. Developed in direct response to customer feedback, i-BELT addresses one of modern manufacturing’s most complex challenges: finding a single partner capable of combining process know-how, operational technology (OT), and information technology (IT).

From products to results: The origins of i-BELT

As industrial environments grew increasingly complex, Omron realized that simply providing solutions based on automation hardware and advanced applications was no longer enough. Manufacturers consistently described the same scenario: consultants deliver reports but no results; IT integrators understand data pipelines but have little grasp of practical manufacturing requirements; and automation specialists optimize machines but fail to connect them to enterprise systems.

The name i-BELT reflects the service’s DNA: the "i" refers to Omron’s three innovative automation principles—integrated, intelligent, and interactive. The term "Belt" originates from Lean Six Sigma, where various belts signify mastery of process optimization and continuous improvement. i-BELT combines deep manufacturing know-how with digital expertise, outlining a structured path of continuous improvement toward the digital smart factory.

Bridging the gap: Process, OT, and IT from a single source

i-BELT rests on two closely interconnected pillars: on one hand, digital Lean transformation, which uses Lean principles and targeted digitalization to drive measurable improvements in productivity, quality, energy consumption, and lead times. On the other, IT/OT convergence, which establishes a scalable, real-time data infrastructure to embed these improvements permanently across the entire enterprise.

While other providers typically excel in only one of these areas, Omron combines all three competencies: deep manufacturing process know-how, OT automation expertise, and enterprise IT integration. This is made possible by the Advanced Solutions Division, as well as through collaboration with Cognizant and a broad ecosystem of technology partners.

Karthigeyan Vadivel, Regional Manager of the Advanced Solutions Division at Omron EMEA, explains: "What we hear time and again from operations and plant managers is that they are caught in the middle. They have digital ambitions, but lack a partner willing to take responsibility for the entire journey. i-BELT was launched to change exactly that. We go into the plants, understand the processes, identify the gaps, and stay until results are achieved."

More than consulting: An accountable partner for reliable implementation

i-Belt is a comprehensive, single-source project designed to break the cycle of failed pilot projects. The process begins with a thorough analysis of manufacturing operations: interviews with on-site teams, KPI evaluation, and process flow mapping. For most manufacturing companies, assembling the right in-house combination of manufacturing experts, IT/OT architects, solution engineers, data scientists, and project managers is simply not realistic. Omron’s interdisciplinary team bridges this gap with specialized expertise—skills that are increasingly hard to find on the market—acting as an extension of the customer’s own development teams. Rather than merely delivering a report, Omron takes responsibility for the entire transformation cycle: from implementation and iteration to continuous improvement.

In practice, OEE improvements of 5% to over 30% can be achieved, alongside reductions in cycle times, scrap rates, and energy consumption. This model of accountability sets i-BELT apart from other automation providers, who may offer targeted consulting or proprietary platforms but rarely coordinate the project end-to-end.

Built for today’s factory and tomorrow’s smart factory

Whether modernizing an existing plant or building a new greenfield facility, i-BELT is designed to meet manufacturing companies exactly where they are. The service is technology-agnostic and compatible with all existing MES, ERP, or automation infrastructures, regardless of the manufacturer. i-BELT identifies the missing components and integrates them in a targeted manner. Existing systems are retained, costly overhauls are avoided, and the system evolves step-by-step into a connected, data-driven smart factory.

Alexander Myagkov, Senior General Manager of the Advanced Solutions Division at Omron Industrial Automation Business, summarizes: "European manufacturing companies have already begun their digital journey. They do not need to start from scratch. Our task is to identify what is missing, integrate it seamlessly, and get the entire system up and running. This openness is a fundamental principle of our approach."

Omron’s global manufacturing expertise, combined with local EMEA delivery teams and an ecosystem of technology and service partners, ensures both the technical depth and the on-site presence required for transformation programs.