Improving Unit Costs through Real-Time Monitoring of Digital Transformation Processes in Manufacturing Enterprises

This study provides a detailed examination of the effects of digital transformation on energy efficiency and cost optimization within the broad application spectrum of Industry 4.0 technologies, focusing on a company in the plastics sector utilizing injection molding machines. The research was conducted as part of a digital transformation project implemented on 10 injection molding machines at a well-established PVC pipe fittings manufacturer in Istanbul, which has been operating for over 40 years. By employing energy analyzers and real-time data monitoring systems, data envelopment analysis (DEA) was performed to evaluate machine efficiencies based on the collected data. The study highlights the multifaceted benefits of digital transformation, emphasizing its impact in critical areas such as sustainable production, competitive advantage, and carbon footprint reduction. The findings demonstrate the strategic significance of digitalization in ensuring business continuity, even under extraordinary conditions such as the COVID-19 pandemic and the global energy crisis. This research presents concrete evidence of the transformative potential of digital transformation in enhancing operational efficiency and cost management, particularly for enterprises with energy-intensive production processes. Keyword: Energy efficiency, cost optimization, industrial digital transformation, Industry 4.0, production systems