Case Studies

Pharmaceuticals Manufacturer

The Challenges

  • Low yield
  • High operational costs
  • Slow ability to detect outliers in production

The Solution

  • Anomaly detection to understand which anomalies affected the success of the batch
  • Yield level prediction for the ongoing batch runs

The Benefits

  • Optimization of the bioreactor process to maximize yield
  • Resource savings in process monitoring and detection of more complex anomalies

Electric Car Battery Cell Producer

The Challenges

  • Unstable production quality with high scrap rates
  • Time-consuming, trial and error -based approach to improve efficiency

The Solution

  • Integration of OT-environment into a data lake
  • Predictive quality analytics to understand which data patterns affect the battery cell quality

The Benefits

  • Scrap rate reduction by 15-19%
  • Reduced ramp-up times 10-15%

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Plywood Manufacturer

The Challenges

  • No visibility to material availability in intermediate storages
  • High unplanned downtime

The Solution

  • 3D Digital Factory to provide end-to-end visibility to all production stages, intermediate storages and logistics between two factories
    • Real-time, continuous productivity performance KPI calculations from sources like ERP and MES

    The Benefits

    • E2E insights brought into one view – no need to look at multiple programs and displays
    • Ability to react fast to problems with real-time visibility to intermediate storages
    • Better decision-making based on real-time data
    • Increased machine uptime

    Electric Car Manufacturer

    The Challenges

    • Lack of material flow visibility
    • Slowness in reacting to increasing customer requests

    The Solution

    • 3D Digital Factory providing real-time visibility to all production stages (material availability, bottlenecks, machine condition etc)

    The Benefits

    • Ability to detect, solve and prevent issues faster
    • Better insight to material demand
    • Ability to make shop-floor adjustments on the fly
    • Overall increased operations efficiency

    Technology System Provider for Automotive Industry

    The Challenges

    • Production monitoring based on historic, manually collected data reports (people, machines, systems)
    • No real-time visibility to machine availability/maintenance status

    The Solution

    • 3D visualization of real-time maintenance status and history for machines and open tickets
    • Connectivity to multiple data sources and systems

    The Benefits

    • Reduced manual efforts
    • Improved machine uptime
    • Improved quality

    Electronics Manufacturer

    The Challenges

    • Unstable production quality when new batches started
    • High waste of components
    • Low OEE

    The Solution

    • 3D visualization of SMT lines
    • Real-time performance dashboards monitoring KPIs
    • Real-time alerts to users when errors detected
    • Anomaly detection

    The Benefits

    • Net Run Time increased by 13% during 6 months
    • OEE improved 13,5% during 6 months
    • Fist Pass Yield improved by 4% during 6 months

    Global Fast Consumer Goods Company

    The Challenges

    • Production loss due to lack of cross-departmental
      visibility into real-time material availability

    The Solution

    • Real-time, role-based views for monitoring key KPIs and material availability across departments
    • Dashboards for management, departments, line managers/operators, inbound/outbound

    The Benefits

    • End-to-end supply chain synchronization
    • Inventory decreased 35%
    • Increased machine uptime