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Posts tagged ‘Manufacturing’

Reinventing After-Sales Service In A Subscription Economy World

  • 91% of manufacturers are investing in predictive analytics in the next 12 months, and 50% consider Artificial Intelligence (AI) a major planned investment for 2019 to support their subscription-based business models.
  • New subscription business models and smart, connected products are freeing manufacturers up from competing for one-time transaction revenues to recurring revenues based on subscriptions.
  • By 2020, manufacturers are predicting 67% of their product portfolios will be smart, connected products according to an excellent study by Capgemini.
  • 71% of manufacturers are using automated sensors for real-time monitoring and data capture of a product’s condition and performance, yet just 25% have the infrastructure in place to analyze it and maximize product uptime.

Manufacturers need to break their dependence on just selling products to selling services if they’re going to grow. Smart, connected products with IoT sensors embedded in them are the future of subscription business models and a key foundation of the subscription economy.

Product Reliability and Uptime Help Create Subscription Economies

In a subscription economy world, whoever excels at product reliability and uptime grows faster than competitors and defines the market. Airlines with the highest on-time ratings have designed in reliability and uptime as part of their company’s identity; their DNA is based on these goals. Worldwide Business Research (WBR) in collaboration with Syncron, a global provider of cloud-based after-sales service solutions focused on empowering the world’s leading manufacturers to maximize product uptime and deliver exceptional customer experiences, recently surveyed to see how manufacturers are addressing the reliability and uptime challenges so critical to growing subscription business.

The research study, Maximized Product Uptime: The Emerging Industry Standard provides insights into how manufacturers can improve their after-sales service solutions. A copy of the study can be downloaded here (PDF, 23 pp., opt-in). Please see pages 20 – 23 for additional details on the report’s methodology. WBR and Syncron designed the survey to gain a deep understanding of manufacturers’ ability to deliver on their customers increasing demand for maximized product uptime, surveying 200 original equipment manufacturers (OEMs), with respondents evenly split between the U.S. and European markets, as well as 100 equipment end-users

Key insights from the study include the following:

  • 34% of manufacturers are ready to compete in a subscription economy and have created a service strategy based on maximized product uptime. 39% are planning to have one in two years, and 22% are predicting it will be in 2020 or later before they have on in place. Capgemini found that manufacturers’ plans for smart, connected products would extend beyond these projections, making it a challenge of manufacturers to realize the new subscription revenue they’re planning on in the future.

  • 71% of manufacturers are using automated sensors including IoT for real-time monitoring and data capture of a product’s condition and performance, yet just 25% have the infrastructure in place to analyze it and maximize product uptime.  51% of manufacturers have systems in place for analyzing the inbound data generated from sensors, yet report they still have more work to do to make them operational.  The 25% of manufacturers with systems in place and at scale will have at least an 18-month jump on competitors who are just now planning on how to make use of the real-time data streams IoT sensors provide.

  • Predicting part failures before they occur (83%), optimizing product functionality based on usage (67%), and using stronger analytics to evaluate product performance (61%) matter most to manufacturers pursuing subscription models. Autonomous product operation (56%) and implementing stronger analytics on ROI ( 50%) are also extremely important. These findings further underscore how manufacturers need to design in reliability and uptime if they are going to succeed with subscription-based business models.

  • 91% of manufacturers are investing in predictive analytics in the next 12 months, and 50% consider Artificial Intelligence (AI) a major planned investment for 2019.  Creating meaningful data models from the massive amount of manufacturing data being captured using automated sensors and IoT devices is making predictive analytics, AI and machine learning extremely important to manufacturers’ IT planning budgets for 2019 and beyond. Combining predictive analytics, AI and machine learning to gain greater insights into pre-emptive maintenance on each production asset, installed product or device is the goal. Knowing when a machine or product will most likely fail is invaluable in ensuring the highest uptime and service reliability levels possible.

  • 77% of manufacturers say having an after-sales service model is critical to their customers’ success today.  Customers are ready to move beyond the legacy transactional, break-fix model of the past and want a more Amazon-like experience when it comes to uptime and reliability of every device they own as consumers and use at work. Speed, scale and simplicity are the foundational elements of a subscription business model, and the majority of manufacturers surveyed say their customers are leading them into a value-added after-sales service model.

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How Blockchain Can Improve Manufacturing In 2019

  • The business value-add of blockchain will grow to slightly more than $176B by 2025, then exceed $3.1T by 2030 according to Gartner.
  • Typical product recalls cost $8M, and many could be averted with improved track-and-traceability enabled by blockchain.
  • Combining blockchain and IoT will revolutionize product safety, track-and-traceability, warranty management, Maintenance, Repair & Overhaul (MRO), and lead to new usage-based business models for smart, connected products.
  • By 2023, 30% of manufacturing companies with more than $5B in revenue will have implemented Industry 4.0 pilot projects using blockchain, up from less than 5% today according to Gartner.

Blockchain’s greatest potential to deliver business value is in manufacturing. Increasing visibility across every area of manufacturing starting with suppliers, strategic sourcing, procurement, and supplier quality to shop floor operations including machine-level monitoring and service, blockchain can enable entirely new manufacturing business models. Supply chains are the foundation of every manufacturing business, capable of making use of blockchain’s distributed ledger structure and block-based approach to aggregating value-exchange transactions to improve supply chain efficiency first. By improving supplier order accuracy, product quality, and track-and-traceability, manufacturers will be able to meet delivery dates, improve product quality and sell more.

Capgemini Research Institute’s recent study, Does blockchain hold the key to a new age of supply chain transparency and trust? provide valuable insights into how blockchain can improve supply chains and manufacturing. A copy of the study is available here (PDF, 32 pp., no opt-in). Capgemini surveyed 731 organizations globally regarding their existing and planned blockchain initiatives. Initial interviews yielded 447 organizations who are currently experimenting with or implementing blockchain. Please see pages 25 & 26 of the study for additional details regarding the methodology.

Key takeaways of the study include the following:

  • Typical product recalls cost $8M, and many could be averted with improved track-and-traceability enabled by blockchain. Capgemini found that there was 456 food recalls alone in the U.S. last year, costing nearly $3.5B. Blockchain’s general ledger structure provides a real-time audit trail for all transactions secured against modifications making it ideal for audit and compliance-intensive industries.

  • Gaining greater cost savings (89%), enhancing traceability (81%) and enhancing transparency (79%) are the top three drivers behind manufacturer’s blockchain investments today. Additional drivers include increasing revenues (57%), reducing risks (50%), creating new business opportunities (44%) and being more customer-centric (38%). The following graphic from the study illustrates the manufacturer’s priorities for blockchain. Capgemini finds that improving track-and-traceability is a primary driver across all manufacturers, consistent with the broader trend of manufacturers adopting software applications that improve this function today. That’s also understandable given how additional regulatory compliance requirements are coming in 2019 and those manufacturers competing in highly regulated industries including aerospace & defense, medical devices, and pharma are exploring how blockchain can give them a competitive edge now

  • Digital marketplaces, tracking critical supply chain parameters, tracking components quality, preventing counterfeit products, and tracking asset maintenance are the five areas Capgemini predicts blockchain will see the greatest adoption. Based on interviews with industry experts and startups, Capgemini found 24 blockchain use cases which are compared by level of adoption and complexity in the graphic below. The use cases reflect how managing supplier contracts is already emerging as one of the most popular blockchain use cases for manufacturing organizations today and will accelerate as compliance becomes even more important in 2019.

  • Manufacturers have the most at-scale deployments of blockchain today, leading all industries included in the study. Blockchain adoption is still nascent across all industries included in the study, with 6% of manufacturers having at-scale implementations today. Customer products manufacturers lead in pilots, with 15% actively [purusing blockchain in limited scope today. And retailers trail all industries with 91% having only proofs of concept.

  • Combining IoT and blockchain at the shipping container level in supply chains increases authenticity, transparency, compliance to product and contractual requirements while reducing counterfeiting. In highly regulated industries including Aerospace & Defense (A&D), Consumer Packaged Goods (CPG), medical devices, and pharma, combining IoT and blockchain provides real-time data on the shipping container conditions, tamper-proof storage, each shipment’s locational history and if there have been changes in temperature and product condition. Capgemini sees use cases where a change in a shipment’s temperature as measured by a sensor change sends alerts regarding contractual compliance of perishable meats and produce, averting the potential of bad product quality and rejected shipments once they reach their destination.

  • Capgemini found that 13% of manufacturers are Pacesetters and are either implementing blockchain at scale or have pilots in at least one site. Over 60% of Pacesetters believe that blockchain is already transforming the way they collaborate with their partners. Encouraged by these results, Pacesetters are set to increase their blockchain investment by 30% in the next three years. They lead early stage experimenters and all implementers on three core dimensions of organizational readiness. These include end-to-end visibility across functions, detailed and defined supportive processes, and availability of the right talent to succeed.

  • Lack of a clear ROI, immature technology and regulatory challenges are the top three hurdles Pacesetter-class manufacturers face in getting blockchain initiatives accepted and into production. All implementations face these three challenges in addition to having to overcome the lack of complementary IT systems at the partner organizations. The following graphic compares the hurdles all manufacturers face in getting blockchain projects implemented by the level of manufacturers adoption success (Pacesetter, early-stage experimenters, all implementers).

Source: Capgemini Research Institute, Does blockchain hold the key to a new age of supply chain transparency and trust? October, 2018

10 Ways To Improve Cloud ERP With AI And Machine Learning

Capitalizing on new digital business models and the growth opportunities they provide are forcing companies to re-evaluate ERP’s role. Made inflexible by years of customization, legacy ERP systems aren’t delivering what digital business models need today to scale and grow.

Legacy ERP systems were purpose-built to excel at production consistency first at the expense of flexibility and responsiveness to customers’ changing requirements. By taking a business case-based approach to integrating Artificial Intelligence (AI) and machine learning into their platforms, Cloud ERP providers can fill the gap legacy ERP systems can’t.

Closing Legacy ERP Gaps With Greater Intelligence And Insight

Companies need to be able to respond quickly to unexpected, unfamiliar and unforeseen dilemmas with smart decisions fast for new digital business models to succeed. That’s not possible today with legacy ERP systems. Legacy IT technology stacks and the ERP systems they are built on aren’t designed to deliver the data needed most.

That’s all changing fast. A clear, compelling business model and successful execution of its related strategies are what all successful Cloud ERP implementations share. Cloud ERP platforms and apps provide organizations the flexibility they need to prioritize growth plans over IT constraints. And many have taken an Application Programming Interface (API) approach to integrate with legacy ERP systems to gain the incremental data these systems provide. In today’s era of Cloud ERP, rip-and-replace isn’t as commonplace as reorganizing entire IT architectures for greater speed, scale, and customer transparency using cloud-first platforms.

New business models thrive when an ERP system is constantly learning. That’s one of the greatest gaps between what Cloud ERP platforms’ potential and where their legacy counterparts are today. Cloud platforms provide greater integration options and more flexibility to customize applications and improve usability which is one of the biggest drawbacks of legacy ERP systems. Designed to deliver results by providing AI- and machine learning insights, Cloud ERP platforms, and apps can rejuvenate ERP systems and their contributions to business growth.

The following are the 10 ways to improve Cloud ERP with AI and machine learning, bridging the information gap with legacy ERP systems:

  1. Cloud ERP platforms need to create and strengthen a self-learning knowledge system that orchestrates AI and machine learning from the shop floor to the top floor and across supplier networks. Having a cloud-based infrastructure that integrates core ERP Web Services, apps, and real-time monitoring to deliver a steady stream of data to AI and machine learning algorithms accelerates how quickly the entire system learns. The Cloud ERP platform integration roadmap needs to include APIs and Web Services to connect with the many suppliers and buyer systems outside the walls of a manufacturer while integrating with legacy ERP systems to aggregate and analyze the decades of data they have generated.

  1. Virtual agents have the potential to redefine many areas of manufacturing operations, from pick-by-voice systems to advanced diagnostics. Apple’s Siri, Amazon’s Alexa, Google Voice, and Microsoft Cortana have the potential to be modified to streamline operations tasks and processes, bringing contextual guidance and direction to complex tasks. An example of one task virtual agents are being used for today is guiding production workers to select from the correct product bin as required by the Bill of Materials. Machinery manufacturers are piloting voice agents that can provide detailed work instructions that streamline configure-to-order and engineer-to-order production. Amazon has successfully partnered with automotive manufacturers and has the most design wins as of today. They could easily replicate this success with machinery manufacturers.

  1. Design in the Internet of Things (IoT) support at the data structure level to realize quick wins as data collection pilots go live and scale. Cloud ERP platforms have the potential to capitalize on the massive data stream IoT devices are generating today by designing in support at the data structure level first. Providing IoT-based data to AI and machine learning apps continually will bridge the intelligence gap many companies face today as they pursue new business models. Capgemini has provided an analysis of IoT use cases shown below, highlighting how production asset maintenance and asset tracking are quick wins waiting to happen. Cloud ERP platforms can accelerate them by designing in IoT support.

  1. AI and machine learning can provide insights into how Overall Equipment Effectiveness (OEE) can be improved that aren’t apparent today. Manufacturers will welcome the opportunity to have greater insights into how they can stabilize then normalize OEE performance across their shop floors. When a Cloud ERP platform serves as an always-learning knowledge system, real-time monitoring data from machinery and production assets provide much-needed insights into areas for improvement and what’s going well on the shop floor.

  1. Designing machine learning algorithms into track-and-traceability to predict which lots from which suppliers are most likely to be of the highest or lowest quality. Machine learning algorithms excel at finding patterns in diverse data sets by continually applying constraint-based algorithms. Suppliers vary widely in their quality and delivery schedule performance levels. Using machine learning, it’s possible to create a track-and-trace application that could indicate which lot from which supplier is the riskiest and those that are of exceptional quality as well.
  2. Cloud ERP providers need to pay attention to how they can help close the configuration gap that exists between PLM, CAD, ERP and CRM systems by using AI and machine learning. The most successful product configuration strategies rely on a single, lifecycle-based view of product configurations. They’re able to alleviate the conflicts between how engineering designs a product with CAD and PLM, how sales & marketing sell it with CRM, and how manufacturing builds it with an ERP system. AI and machine learning can enable configuration lifecycle management and avert lost time and sales, streamlining CPQ and product configuration strategies in the process.
  3. Improving demand forecasting accuracy and enabling better collaboration with suppliers based on insights from machine learning-based predictive models is attainable with higher quality data. By creating a self-learning knowledge system, Cloud ERP providers can vastly improve data latency rates that lead to higher forecast accuracy. Factoring in sales, marketing, and promotional programs further fine-tunes forecast accuracy.
  4. Reducing equipment breakdowns and increasing asset utilization by analyzing machine-level data to determine when a given part needs to be replaced. It’s possible to capture a steady stream of data on each machine’s health level using sensors equipped with an IP address. Cloud ERP providers have a great opportunity to capture machine-level data and use machine learning techniques to find patterns in production performance by using a production floor’s entire data set. This is especially important in process industries where machinery breakdowns lead to lost sales. Oil refineries are using machine learning models comprise more than 1,000 variables related to material input, output and process perimeters including weather conditions to estimate equipment failures.
  5. Implementing self-learning algorithms that use production incident reports to predict production problems on assembly lines needs to happen in Cloud ERP platforms. A local aircraft manufacturer is doing this today by using predictive modeling and machine learning to compare past incident reports. With legacy ERP systems these problems would have gone undetected and turned into production slowdowns or worse, the line having to stop.
  6. Improving product quality by having machine learning algorithms aggregate, analyze and continually learn from supplier inspection, quality control, Return Material Authorization (RMA) and product failure data. Cloud ERP platforms are in a unique position of being able to scale across the entire lifecycle of a product and capture quality data from the supplier to the customer. With legacy ERP systems manufacturers most often rely on an analysis of scrap materials by type or caused followed by RMAs. It’s time to get to the truth about why products fail, and machine learning can deliver the insights to get there.

10 Ways Machine Learning Is Revolutionizing Manufacturing In 2018

  • Improving semiconductor manufacturing yields up to 30%, reducing scrap rates, and optimizing fab operations is achievable with machine learning.
  • Reducing supply chain forecasting errors by 50% and lost sales by 65% with better product availability is achievable with machine learning.
  • Automating quality testing using machine learning is increasing defect detection rates up to 90%.

Bottom line: Machine learning algorithms, applications, and platforms are helping manufacturers find new business models, fine-tune product quality, and optimize manufacturing operations to the shop floor level.

Manufacturers care most about finding new ways to grow, excel at product quality while still being able to take on short lead-time production runs from customers. New business models often bring the paradox of new product lines that strain existing ERP, CRM and PLM systems by the need always to improve time-to-customer performance. New products are proliferating in manufacturing today, and delivery windows are tightening. Manufacturers are turning to machine learning to improve the end-to-end performance of their operations and find a performance-based solution to this paradox.

The ten ways machine learning is revolutionizing manufacturing in 2018 include the following:

  • Improving semiconductor manufacturing yields up to 30%, reducing scrap rates, and optimizing fab operations are is achievable with machine learning. Attaining up to a 30% reduction in yield detraction in semiconductor manufacturing, reducing scrap rates based on machine learning-based root-cause analysis and reducing testing costs using AI optimization are the top three areas where machine learning will improve semiconductor manufacturing. McKinsey also found that AI-enhanced predictive maintenance of industrial equipment will generate a 10% reduction in annual maintenance costs, up to a 20% downtime reduction and 25% reduction in inspection costs. Source: Smartening up with Artificial Intelligence (AI) – What’s in it for Germany and its Industrial Sector? (52 pp., PDF, no opt-in) McKinsey & Company.

  • Asset Management, Supply Chain Management, and Inventory Management are the hottest areas of artificial intelligence, machine learning and IoT adoption in manufacturing today. The World Economic Forum (WEF) and A.T. Kearney’s recent study of the future of production find that manufacturers are evaluating how combining emerging technologies including IoT, AI, and machine learning can improve asset tracking accuracy, supply chain visibility, and inventory optimization. Source: Technology and Innovation for the Future of Production: Accelerating Value Creation (38 pp., PDF, no opt-in) World Economic Forum with A.T. Kearney.

  • Manufacturer’s adoption of machine learning and analytics to improve predictive maintenance is predicted to increase 38% in the next five years according to PwC. Analytics and MI-driven process and quality optimization are predicted to grow 35% and process visualization and automation, 34%. PwC sees the integration of analytics, APIs and big data contributing to a 31% growth rate for connected factories in the next five years. Source: Digital Factories 2020: Shaping the future of manufacturing (48 pp., PDF, no opt-in) PriceWaterhouseCoopers

  • McKinsey predicts machine learning will reduce supply chain forecasting errors by 50% and reduce lost sales by 65% with better product availability. Supply chains are the lifeblood of any manufacturing business. Machine learning is predicted to reduce costs related to transport and warehousing and supply chain administration by 5 to 10% and 25 to 40%, respectively. Due to machine learning, overall inventory reductions of 20 to 50% are possible. Source: Smartening up with Artificial Intelligence (AI) – What’s in it for Germany and its Industrial Sector? (52 pp., PDF, no opt-in) McKinsey & Company.

  • Improving demand forecast accuracy to reduce energy costs and negative price variances using machine learning uncovers price elasticity and price sensitivity as well. Honeywell is integrating AI and machine-learning algorithms into procurement, strategic sourcing and cost management. Source: Honeywell Connected Plant: Analytics and Beyond. (23 pp., PDF, no opt-in) 2017 Honeywell User’s Group.

  • Automating inventory optimization using machine learning has improved service levels by 16% while simultaneously increasing inventory turns by 25%. AI and machine learning constraint-based algorithms and modeling are making it possible scale inventory optimization across all distribution locations, taking into account external, independent variables that affect demand and time-to-customer delivery performance. Source: Transform the manufacturing supply chain with Multi-Echelon inventory optimization, Microsoft, March 1, 2018.

  • Combining real-time monitoring and machine learning is optimizing shop floor operations, providing insights into machine-level loads and production schedule performance. Knowing in real-time how each machine’s load level impacts overall production schedule performance leads to better decisions managing each production run. Optimizing the best possible set of machines for a given production run is now possible using machine learning algorithms. Source: Factories of the Future: How Symbiotic Production Systems, Real-Time Production Monitoring, Edge Analytics and AI Are Making Factories Intelligent and Agile, (43 pp., PDF, no opt-in) Youichi Nonaka, Senior Chief Researcher, Hitachi R&D Group and Sudhanshu Gaur Director, Global Center for Social Innovation Hitachi America R&D

  • Improving the accuracy of detecting costs of performance degradation across multiple manufacturing scenarios reduces costs by 50% or more. Using real-time monitoring technologies to create accurate data sets that capture pricing, inventory velocity, and related variables gives machine learning apps what they need to determine cost behaviors across multiple manufacturing scenarios. Source: Leveraging AI for Industrial IoT (27 pp., PDF, no opt-in) Chetan Gupta, Ph.D. Chief Data Scientist, Big Data Lab, Hitachi America Ltd. Date: Sept. 19th, 2017

  • A manufacturer was able to achieve a 35% reduction in test and calibration time via accurate prediction of calibration and test results using machine learning. The project’s goal was to reduce test and calibration time in the production of mobile hydraulic pumps. The methodology focused on using a series of machine learning models that would predict test outcomes and learn over time. The process workflow below was able to isolate the bottlenecks, streamlining test and calibration time in the process. Source: The Value Of Data Science Standards In Manufacturing Analytics (13 pp., PDF, no opt-in) Soundar Srinivasan, Bosch Data Mining Solutions And Services

  • Improving yield rates, preventative maintenance accuracy and workloads by the asset is now possible by combining machine learning and Overall Equipment Effectiveness (OEE). OEE is a pervasively used metric in manufacturing as it combines availability, performance, and quality, defining production effectiveness. Combined with other metrics, it’s possible to find the factors that impact manufacturing performance the most and least. Integrating OEE and other datasets in machine learning models that learn quickly through iteration are one of the fastest growing areas of manufacturing intelligence and analytics today. Source: TIBCO Manufacturing Solutions, TIBCO Community, January 30, 2018

Additional reading:

Artificial Intelligence (AI) Delivering Breakthroughs in Industrial IoT (26 pp., PDF, no opt-in) Hitachi

Artificial Intelligence and Robotics and Their Impact on the Workplace (120 pp., PDF, no opt-in) IBA Global Employment Institute

Artificial Intelligence: The Next Digital Frontier? (80 pp., PDF, no opt-in) McKinsey and Company

Big Data Analytics for Smart Manufacturing: Case Studies in Semiconductor Manufacturing (20 pp., PDF, no opt-in), Applied Materials, Applied Global Services

Connected Factory and Digital Manufacturing: A Competitive Advantage, Shantanu Rai, HCL Technologies (36 pp., PDF, no opt-in)

Demystifying AI, Machine Learning, and Deep Learning, DZone, AI Zone

Digital Factories 2020: Shaping the future of manufacturing (48 pp., PDF, no opt-in) PriceWaterhouseCoopers

Emerging trends in global advanced manufacturing: Challenges, Opportunities, And Policy Responses (76 pp., PDF, no opt-in) University of Cambridge

Factories of the Future: How Symbiotic Production Systems, Real-Time Production Monitoring, Edge Analytics and AI Are Making Factories Intelligent and Agile, (43 pp., PDF, no opt-in) Youichi Nonaka, Senior Chief Researcher, Hitachi R&D Group and Sudhanshu Gaur Director, Global Center for Social Innovation Hitachi America R&D

Get started with the Connected factory preconfigured solution, Microsoft Azure

Honeywell Connected Plant: Analytics and Beyond. (23 pp., PDF, no opt-in) 2017 Honeywell User’s Group.

Impact of the Fourth Industrial Revolution on Supply Chains (22 pp., PDF, no opt-in) World Economic Forum

Leveraging AI for Industrial IoT (27 pp., PDF, no opt-in) Chetan Gupta, Ph.D. Chief Data Scientist, Big Data Lab, Hitachi America Ltd. Date: Sept. 19th, 2017

Machine Learning & Artificial Intelligence Presentation (14 pp., PDF, no opt-in) Erik Hjerpe Volvo Car Group

Machine Learning Techniques in Manufacturing Applications & Caveats, (44 pp., PDF, no opt-in), Thomas Hill, Ph.D. | Exec. Director Analytics, Dell

Machine learning: the power and promise of computers that learn by example (128 pp., PDF, no opt-in) Royal Society UK

Predictive maintenance and the smart factory (8 pp., PDF, no opt-in) Deloitte

Priore, P., Gómez, A., Pino, R., & Rosillo, R. (2014). Dynamic scheduling of manufacturing systems using machine learning: An updated reviewAi Edam28(1), 83-97.

Smartening up with Artificial Intelligence (AI) – What’s in it for Germany and its Industrial Sector? (52 pp., PDF, no opt-in) McKinsey & Company

Technology and Innovation for the Future of Production: Accelerating Value Creation (38 pp., PDF, no opt-in) World Economic Forum with A.T. Kearney

The Future of Manufacturing; Making things in a changing world (52 pp., PDF, no opt-in) Deloitte University Press

The transformative potential of AI in the manufacturing industry, Microsoft, by Sanjay Ravi, Managing Director, Worldwide Discrete Manufacturing, Microsoft, September 25, 2017

The Value Of Data Science Standards In Manufacturing Analytics (13 pp., PDF, no opt-in) Soundar Srinivasan, Bosch Data Mining Solutions And Services

TIBCO Manufacturing Solutions, TIBCO Community, January 30, 2018

Transform the manufacturing supply chain with Multi-Echelon inventory optimization, Microsoft, March 1, 2018.

Turning AI into concrete value: the successful implementers’ toolkit (28 pp., PDF, no opt-in) Capgemini Consulting

Wuest, T., Weimer, D., Irgens, C., & Thoben, K. D. (2016). Machine learning in manufacturing: advantages, challenges, and applicationsProduction & Manufacturing Research4(1), 23-45.

Ten Ways Big Data Is Revolutionizing Manufacturing

quality1McKinsey & Company recently published How Big Data Can Improve Manufacturing which provides insightful analysis of how big data and advanced analytics can streamline biopharmaceutical, chemical and discrete manufacturing.

The article highlights how manufacturers in process-based industries are using advanced analytics to increase yields and reduce costs. Manufacturers have an abundance of operational and shop floor data that is being used for tracking today.  The McKinsey article shows through several examples how big data and advanced analytics applications and platforms can deliver operational insights as well.

The following graphic from the article illustrates how big data and advanced analytics are streamlining manufacturing value chains by finding the core determinants of process performance, and then taking action to continually improve them:

Advanced Analytics Big Data in Manufacturing

Big Data’s Impact on Manufacturing Is Growing

In addition to the examples provided in the McKinsey article, there are ten ways big data is revolutionizing manufacturing:

  • Increasing the accuracy, quality and yield of biopharmaceutical production.  It is common in biopharmaceutical production flows to monitor more than 200 variables to ensure the purity of the ingredients as well as the substances being made stay in compliance. One of the many factors that makes biopharmaceutical production so challenging is that yields can vary from 50 to 100% for no immediately discernible reason. Using advanced analytics, a manufacturer was able to track the nine parameters that most explained yield variation. Based on this insight they were able to increase the vaccine’s yield by 50%, worth between $5M to $10M in yearly savings for the single vaccine alone.
  • Accelerating the integration of IT, manufacturing and operational systems making the vision of Industrie 4.0 a reality. Industrie 4.0 is a German government initiative that promotes automation of the manufacturing industry with the goal of developing Smart Factories. Big data is already being used for optimizing production schedules based on supplier, customer, machine availability and cost constraints. Manufacturing value chains in highly regulated industries that rely on German suppliers and manufacturers are making rapid strides with Industrie 4.0 today.  As this initiative serves as a catalyst to galvanize diverse multifunctional departments together, big data and advanced analytics will become critical to its success.
  • Better forecasts of product demand and production (46%), understanding plant performance across multiple metrics (45%) and providing service and support to customers faster (39%) are the top three areas big data can improve manufacturing performance.   These findings are from a recent survey LNS Research and MESA International completed to see where big data is delivering the greatest manufacturing performance improvements today. You can find the original blog post here.

LNS Graphic

  • Integrating advanced analytics across the Six Sigma DMAIC (Define, Measure, Analyze, Improve and Control) framework to fuel continuous improvement.  Getting greater insights into how each phase of a DMAIC-driven improvement program is working, and how the efforts made impact all other areas of manufacturing performance is nascent today. This area shows great potential to make production workflows more customer-driven than ever before.
  • Greater visibility into supplier quality levels, and greater accuracy in predicting supplier performance over time.  Using big data and advanced analytics, manufacturers are able to view product quality and delivery accuracy in real-time, making trade-offs on which suppliers receive the most time-sensitive orders.  Managing to quality metrics becomes the priority over measuring delivery schedule performance alone.
  • Measuring compliance and traceability to the machine level becomes possible. Using sensors on all machinery in a production center provides operations managers with immediate visibility into how each is operating. Having advanced analytics can also show quality, performance and training variances by each machine and its operators.  This is invaluable in streamlining workflows in a production center, and is becoming increasingly commonplace.
  • Selling only the most profitable customized or build-to-order configurations of products that impact production the least.  For many complex manufacturers, customized or build-to-order products deliver higher-than-average gross margins yet also costs exponentially more if production processes aren’t well planned.  Using advanced analytics, manufacturers are discovering which of the myriad of build-to-order configurations they can sell with the most minimal impact to existing production schedules to the machine scheduling, staffing and shop floor level.
  • Breaking quality management and compliance systems out of their silos and making them a corporate priority.  It’s time for more manufacturers to take a more strategic view of quality and quit being satisfied with standalone, siloed quality management and compliance systems.  The McKinsey article and articles listed at the end of this post provide many examples of how big data and analytics are providing insights into which parameters matter most to quality management and compliance. The majority of these parameters are corporate-wide, not just limited to quality management or compliance departments alone.
  • Quantify how daily production impacts financial performance with visibility to the machine level. Big data and advanced analytics are delivering the missing link that can unify daily production activity to the financial performance of a manufacturer.  Being able to know to the machine level if the factory floor is running efficiently, production planners and senior management know how best to scale operations.  By unifying daily production to financial metrics, manufacturers have a greater chance of profitably scaling their operations.
  • Service becomes strategic and a contributor to customers’ goals by monitoring products and proactively providing preventative maintenance recommendations.  Manufacturers are starting to look at the more complex products they produce as needing an operating system to manage the sensors onboard. These sensors report back activity and can send alerts for preventative maintenance. Big data and analytics will make the level of recommendations contextual for the first time so customers can get greater value.  General Electric is doing this today with its jet engines and drilling platforms for example.

Additional sources of information on Big Data in Manufacturing:

 

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