Industry 4.0 transformation across global manufacturing network

Nexans is strengthening operational performance across its worldwide manufacturing footprint through a systematic Industry 4.0 transformation. By deploying the Fabriq platform to digitalize its performance management standard and embedding operational discipline into daily shopfloor routines, the company has implemented a structured approach to operational excellence across 40 plants in key markets including Europe, North America, and beyond.

This transformation marks a shift from manual, disconnected processes to integrated digital systems that enable real-time decision-making, faster problem-solving, and consistent application of best practices across the global manufacturing network.

The challenge: from manual to digital operations management

For decades, Nexans applied a proven performance management system grounded in physical whiteboards and daily rituals. This hands-on standard remained effective locally, but as the company expanded it became clear that a digital layer was needed to preserve those routines while providing faster visibility, consistent escalation and quicker sharing of solutions across sites:

• Limited visibility: plant leaders lacked real-time insight into performance across the network
• Inconsistent escalation: problems requiring attention sometimes went unresolved or delayed resolution
• Fragmented best practices: solutions developed in one plant took time to reach others
• Shopfloor friction: operators spent time on administrative tasks rather than solving problems

Nexans recognized that accelerating its Industry 4.0 journey required not just new technology, but a rethinking of how plants manage performance on a daily basis. The Group therefore sought to digitize and scale its proven daily routines so frontline teams could retain operational discipline while gaining real-time data and faster cross-site learning.

The transformation: bringing operational discipline to the digital shopfloor

Nexans implemented a structured approach to plant performance management using the Fabriq platform, which digitalizes and energizes its existing operational standard, not replacing it, but extending it with new capabilities. Fabriq serves as the technical backbone, translating Nexans’ operational discipline into a user-friendly digital interface that frontline teams adopt rapidly.

Fabriq is one of several levers in Nexans’ broader Industry 4.0 programme, alongside automation, data infrastructure and predictive maintenance; the platform is today one of the most advanced modules in deployment, with a focused scope on shopfloor performance and daily operational discipline.

Nexans initiated its pilot at Autun (France). Drawing on the lessons from this pilot, the company then progressively rolled out the solution to other plants as part of Nexans’ global deployment plan, including later deployments at sites such as Charleston (United States).

Autun (France): pilot

The Autun plant hosted the initial pilot of the Fabriq-based approach. Teams there tested the digital daily boards to support shift handovers, structured problem-solving and performance reviews. Operators and team leaders adopted the interface rapidly, finding it simplified daily work, reduced administrative friction and helped embed more consistent routines.

Results at Autun demonstrate improvements in:

• Safety and quality metrics
• Operational responsiveness
• Team communication and coordination
• Operator engagement and simplification of daily work.

Charleston (US): local rollout

The Charleston plant launched its transformation using insights from the Autun pilot and deploying Fabriq while adapting to local operational realities. Drawing on lessons from Autun and other plants in the global deployment, Charleston deployed Fabriq across its production teams, validating the model in a different operational context.

Nexans’ Industry 4.0 transformation delivers measurable gains at three levels of the organization:

At operational level (shopfloor teams):

• Faster execution and problem resolution
• Better prioritization of critical issues
• Improved escalation and issue tracking
• Real-time access to performance data

At plant level (site leadership):

• Improved visibility of overall performance and key issues
• Measurable impact on safety, quality, delivery, costs, and working environment
• Faster root-cause analysis and corrective action

At Group level (company-wide):

• Stronger, consistent application of operational standards
• Harmonization of best practices across 40 plants
• Ability to prevent or accelerate resolution of recurring issues globally.

Building the ecosystem: governance and support

Nexans’ transformation is embedded in a broader Industry 4.0 ecosystem supported by Schneider Electric, its strategic partner for digital transformation. This partnership ensures that Fabriq and related solutions are integrated into a robust, scalable infrastructure, avoiding siloed tools and creating a foundation for future expansion.

The deployment model includes:

• Central Industrial team providing governance and strategic direction
• Network of key users in each plant, empowered as local champions
• Structured training programs (on-site and online) for consistent capability-building
• Regular knowledge-sharing sessions across the manufacturing network.

What’s next: from daily control to weekly performance steering

Nexans’ current phase focuses on daily operational discipline, monitoring performance, confirming alignment with standards, and taking quick action when needed. The next phase will introduce weekly performance steering, enabling teams to:

• Identify recurrent deviations from standards
• Conduct root-cause-oriented problem-solving
• Document and share lessons learned across plants.

By scaling this approach, Nexans aims to prevent problems globally: a solution developed in one plant becomes a best practice that prevents or accelerates resolution elsewhere.

Planned extensions include generalizing the platform for recurring routines:

• Shift handovers (night, morning, afternoon rotations)
• Equipment start-up procedures
• First-level maintenance checklists
• 5S organization audits
• Safety audit protocols

To showcase the transformation in action, Nexans and Fabriq have co-produced a series of Return on Experience (REX) videos with teams at Autun and Charleston.