Guwahati: Hindustan Unilever Limited’s (HUL) Doom Dooma factory in Tinsukia, Assam, has earned global acclaim for its innovation and excellence. The factory has been recognised as an Advanced Fourth Industrial Revolution (4IR) End-to-End Value Chain Lighthouse by the World Economic Forum (WEF) on January 14.
With this recognition, Doom Dooma joins HUL’s Dapada site, honored in 2022, and Sonepat site, recognised in 2023, making HUL the only fast-moving consumer goods (FMCG) company in India with three such distinguished factories.
The WEF’s Global Lighthouse Network identifies and celebrates the most digitally advanced factories worldwide, showcasing facilities that utilise cutting-edge technologies like artificial intelligence (AI), automation, cloud computing, and the Internet of Things (IoT) to transform operations, enhance efficiency, and drive sustainable growth. By joining this elite global network, HUL’s Doom Dooma factory underscores its significant contributions to India’s industrial landscape and its role as a pioneer in digital transformation.
In response to the increasing demand for instant delivery in e-commerce, the factory in Tinsukia, operating in a remote region with limited resources, implemented over 50 digital use cases to enhance end-to-end supply chain agility. This transformation was achieved through machine learning-driven planning, AI-enabled changeovers, and a green digital twin, which together helped reduce the planning frozen period from 14 days to one day. These advancements enabled a threefold increase in unique stock-keeping units (SKUs) and cut the time required for sustainable packaging trials by 84%. Additionally, the site contributed to local community development by fostering digital skills through an Industrial Training Institute and a digital-Braille lab, thus bolstering its social impact alongside its technological advancements.
HUL’s Doom Dooma factory is India’s largest Beauty and Wellbeing manufacturing unit, producing over 130 SKUs for iconic brands such as Glow & Lovely, Pond’s, Vaseline, Sunsilk, Clinic Plus, TRESemmé, and Dove. With an annual production capacity exceeding 5.4 billion units and a workforce of 675, the site has revolutionised its operations through the adoption of over 50 digital initiatives across the supply chain. These efforts have significantly improved product quality and workforce development in this remote area.
Key technological advancements driving this transformation include AI-powered product changeovers, which have reduced changeover times by 85%, enhancing e-commerce efficiency by enabling rapid, one-click transitions between products. The use of generative AI to analyse consumer feedback with 97% accuracy has allowed swift product quality improvements. AI-driven digital planning systems now analyse over 10,000 product combinations, reducing the planning frozen period to one day and improving product availability by 92%. The factory’s adoption of a digital twin approach has cut laminate plastic waste by 60% and reduced virgin plastic use by 21% through virtual simulations and operational testing. Additionally, an AI-powered workforce allocation tool has increased labor productivity by 400%, optimising workforce deployment and delivering targeted training programs.
HUL CEO and Managing Director Rohit Jawa expressed pride in the recognition, stating that by integrating advanced technologies, the company has revolutionised operations, significantly enhancing productivity and product quality. He emphasised that these initiatives not only benefit the business but also represent a significant step towards building a better future. Yogesh Mishra, Executive Director of Supply Chain at HUL, highlighted that the recognition underscores the company’s commitment to leveraging technology to drive efficiency, sustainability, and growth across its operations.
Kiva Allgood, Head of the Centre for Advanced Manufacturing and Supply Chains at WEF, highlighted the significance of the Global Lighthouse Network, emphasising that the recognised sites exemplify sustainable innovation. According to Allgood, these facilities set benchmarks that millions can follow to drive transformational change across the entire ecosystem.
The Global Lighthouse Network, launched in 2018, celebrates the world’s most innovative manufacturing sites and spans over 30 countries and 35 sectors. It features 189 sites, 25 of which are Sustainability Lighthouses. Co-founded by the World Economic Forum and McKinsey & Company, the network serves as a platform for sharing best practices and shaping the future of global manufacturing.
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