Clients

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DataProphet PRESCRIBE is a unique deep learning solution that can prescribe optimum plant control parameters, often resulting in 50% or more reductions in the cost of non-quality, through a customized single model approach, while taking into account higher order effects.

Our AI solution for the manufacturing industry is aimed at achieving zero defects in the production process. Using advanced predictive and prescriptive machine learning capabilities, DataProphet can predict defects, faults and quality errors and prescribe optimum control parameters to improve production.

DataProphet's prescriptive AI system, coupled to your data becomes an expert with experience in all of your production history. This AI expert is able to guide your production team to eliminate defects, scrap and minimize downtime.
Animation: We are able to reach into the mind of our AI and understand the complex relationships between processes variables that the system has learned. Using these insights and the current state of your production systems we are able to provide holistic guidance to your production team to eliminate defects, scrap, and minimize downtime.

Because this guidance understands the interactions between all aspects of your production system the holistic guidance creates a single team contributing towards a common goal. This is far more efficient than individual process owners optimising small sections of the plant.
0% Defects
shipped for a period of 3 months
4 - 8
Week deployment
Traceability
inferred through discrete and continuous processes
> 700M records
and 5 - 10k features in a single view
5%
Production Increase
Product Traceability
1M+ Records & 100K Features
In a single view

Why it works

Tracks relationships between process parameters

Despite individual parameters being well within accepted tolerances, the complex interplay between a large number of process parameters still results in increased manufacturing risk in multi-step production processes.

The reason for this increase is the intricate web of interdependencies that exist between past and present steps in manufacturing processes. DataProphet PRESCRIBE can learn the complex relationships existing between parameters, significantly reducing global manufacturing risk in your factory.

Traditional, statistical process control solutions can also account for relationships between multiple process parameters, but DataProphet PRESCRIBE can encompass a far wider range of parameters and track the interactions between them in a dynamic way—resulting in full situational awareness of the manufacturing process.
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Discovers root causes of latent defects

Because of the complex nature of manufacturing processes, some defects only surface after production has started. These types of defects are commonly referred to as ‘latent defects’.

The causes of latent defects are not readily observable. To isolate the root causes of these defects, it is necessary to first establish traceability between components and the manufacturing conditions under which they were produced. Once this traceability has been established, DataProphet PRESCRIBE can identify the relationship between defect frequency and occurrence.
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Manufacturing Case Study


Predicting engine block defects and identifying high yield operating regions.

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Stud Welding Case Study


55% reduction in stud welding defects.

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Product sheet


$400,000 monthly savings and 0% defects on shipments.

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How it works

Our team of experts integrate DataProphet PRESCRIBE into your existing data environment, enabling it to combine your process data and quality data - which may include inferring traceability through otherwise opaque process steps.

Once integrated, DataProphet PRESCRIBE actively pushes optimal prescriptive recommendations to your operators, informing them how to make small process parameter changes to pre-emptively avoid defects or loss in yield.
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Features

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Optimization
DataProphet PRESCRIBE provides dynamic optimisation of your process control system and helps you reduced loss to non-quality in your production line. It achieves this through the active minimization of manufacturing risk.
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Reduce Defects
Defect occurrence is significantly reduced thanks to probability predictions that enhance existing quality control systems.
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Transfer best practices
DataProphet PRESCRIBE provides distillation and maintenance of institutional knowledge embedded in your process data. This feature helps you to more easily transfer best practices between experienced and inexperienced process operators.
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Easy integration
DataProphet PRESCRIBE readily adapts to your manufacturing environment. Our team performs the integration across all common platforms and floor management systems.
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Simulation
DataProphet PRESCRIBE provides you with a learnt digital twin for your factory that allows engineers to simulate the impact of process changes on production output.

Implementation

Implementing DataProphet PRESCRIBE in your factory

It takes four to eight weeks to deploy DataProphet PRESCRIBE in your factory since it needs to be configured to integrate with your unique manufacturing process and infrastructure. At DataProphet, we know that every factory is different and the importance of process parameters may differ significantly from one facility to another.

The integration process primarily involves building the machine learning models that will process your data and extract the most value from it.
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Continuous improvement

DataProphet PRESCRIBE uses your historical process data to learn ideal process parameters for your production line, it will prescribe optimal parameters as soon as it goes online. As part of the implementation process, our team of data science experts will continually work to improve your installation, helping you reach your Industry 4.0 ambitions.

As a customer, you choose which Industry 4.0 technologies we implement in your factory. Our team will work continually to improve your system to provide the best possible return on investment.
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