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Big Data for Manufacturing

Lean production and cost cutting no longer provide the basis of sustainable competitive advantage. Acme One’ 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:

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Key Features of our Solutions

  • 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

Tech Stack

  • Power BI & HDInsight
  • Microsoft Dynamics
  • Azure Stream Analytics
  • Cortana Analytics Suite
  • SQL Server 2014
  • Azure DocumentDB
  • Hortonworks Hadoop Cluster
  • SI (Hortonworks, BigSQL, KAFKA, Splunk, ZooKeeper)
  • IBM BigInsight
  • SAP HANA
  • SQL Azure

Key Benefits

  • Predict design flaws
  • Decrease lost manufacturing capacity
  • Improve Overall Equipment Effectiveness (OEE)
  • Predict machine/plant maintenance requirements
  • Predict production requirements through sales forecasting
  • Offer services related to high-grossing products
  • Improve value ratio by mitigating material transformation delays
  • Improve inventory replenishment time
  • Predict output quality based on product engineering changes

ACME One ignites growth and efficiency, unveiling your business’s hidden potential through our top custom software development services.

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Technology

  • React
  • Python
  • MEAN Stack
  • MERN Stack

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