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80% of companies surveyed in a World Economic Forum paper said "productivity-related objectives" are their main motivators for pursuing advanced analytics in manufacturing. We're highlighting some of the best use cases and breakthroughs.
2023 is the Year of AI
GrayMatter is celebrating the Best of Industrial Analytics — highlighting Advanced Analytics use cases that produce groundbreaking results.
Roughly 80% of companies surveyed in a World Economic Forum paper said "productivity-related objectives" including shop floor automation, quality improvement and net working capital optimization are their main motivators for pursuing advanced analytics in manufacturing.
Today, we're featuring three successful use cases in which GrayMatter clients completed an advanced analytics solution that produced significant savings and met a major production objective.
Improving Quality
ChallengeA premium pet food producer suspects that adjusting a few key ingredients can produce more consistent quality without adding time-consuming lab tests and production start-up delays.
SolutionGrayMatter’s Advanced Industrial Analytics solution predicts when production is in danger of dipping below quality standards and alerts operators to make a change.
Big Wins
- Making in-line changes based on highly relevant data reduced waste
- Allowed first-pass quality improvements
- Made it easier to train technicians
- A 1% reduction in waste produces an estimated seven-figure savings over one year
Reducing Downtime
ChallengeA specialty, engineered plastic film manufacturer needs to predict breakages before they occur so it can reduce downtime and avoid waste and cleanup costs that can reach tens of thousands of dollars per breakage.
SolutionGrayMatter's solution analyzes disparate data about more than 400 early indicators of manufacturing line instability, which can lead to film breaks, and enable early intervention.
Big Wins
- Manufacturing uptime increased from the mid-80s to more than 90%
- Unlocked a savings of more than $500,000 a year
Enhancing Data Visibility
ChallengeA major food producer wants to enable near real-time flow of information to facility operators to optimize production and spread the opportunity to make strategic adjustments from senior leaders to plant floor professionals.
SolutionThe producer has been able to build out its capabilities to spot potential issues early and address them, and then duplicate this success at new and existing facilities.
Big Wins
- Generated six-figure annual savings by reducing product overfill
- Greatly expanded production capacity