Big Data for Manufacturing

Lean production and cost cutting no longer provide the basis of sustainable competitive advantage. Allied Consultants’ Big Data solution for manufacturing includes industry relevant features such as preventive & preemptive maintenance (predicts cause & time of future failures), real-time precision forecasting, product quality monitoring , yield management, etc. Manufacturers can now predict design flaws in advance and improve overall equipment effectiveness (OEE). Following modules are part of the solution:

Predictive & preemptive maintenance
- Monitor performance and up-time of systems and applications as the devices, sensors and equipment sends continuous data
- Fix things before they break and monitor assets (machines, plants) remotely and in real-time

Quality management interface
- Predict, preempt and identify out-of-bounds manufacturing
- Aggregation & modelling of large volumes, high speed and variety of data
- Big Data analytics integration with Six Sigma DMAIC
- Correlation development between quality factors

Yield management
- Big Data analytics to isolate factors that impact production quality
- Batch-to-batch comparisons (by comparing millions of data points) to identify factors that impact plant yield
- Aligns data sets around batch IDs, equipment, time stamps, and other factors that impact production

Production optimization module
- The module optimizes production schedules based on near-real time data acquired from suppliers, customers, machine availability and cost constraints
- Integrated analytics predict the risk of late delivery by suppliers

Closed-loop product management
- Creates closed-loop environment for select products, applies ETL to analyze large volume of product use data for continuous improvement in design & manufacturing process
- Integrates engineering and manufacturing design
- Install embedded sensors into products/equipment to review & optimize production
- Tracks materials logistics in real-time

Forecasting/Demand Forecasting
- Precision forecasting of order lead times
- Forecast sales orders across the geographic regions
- Forecasts part & plant failure by factoring in maintenance records, operating environment data and production schedules
- Graphs, charts and KPI dashboards provide visibility into near-real time inventory to efficiently schedule purchasing

Order management
- A centrally accessible dashboard that contains order cycle information (time in calendar days from order release to manufacturing to customer shipment)
- Historical log of order delivery errors (the dashboard displays delivery/order errors during a defined manufacturing run)
- Displays TAKT (average unit production time) for each product category up-to the batch level; a key metric in lean manufacturing

Warranty claims management
- The module presents aggregated information in form of a GUI. Information includes warranty claims by location, customer segment, frequency of claims and density of claims with respect to geographical areas