STEP TOWARDS ZERO-DEFECT MANUFACTURING
AI-ENABLED SCRAP AND DOWNTIME REDUCTION
DataProphet’s suite of AI solutions for manufacturing analyzes historical and current plant data to provide holistic guidance to your production team. This step towards autonomous manufacturing empowers your people to eliminate defects and scrap, and minimize downtime, without halting production or depending on the availability of external experts. Accelerated, AI-driven diagnoses of complex failures free up machine builders for value-add projects such as diversifying their product lines.
DataProphet PRESCRIBE alerts technicians ahead of time to problems developing on the production line, and suggests specific setpoint changes to process parameters. The outcome? Impending defects are avoided.
AI-DRIVEN PREDICTABLE PLANT PERFORMANCE
The complex interplay between thousands of parameters in multi-step manufacturing processes introduces the risk of production defects. DataProphet PRESCRIBE tracks the relationships between parameters and actively pushes optimal machine setpoint changes to operators, enabling them to pre-emptively avoid defects and loss in yield. In one factory, PRESCRIBE reduced robotic welding defects by 75% and halved the cost of non-quality.
Planned Stops, Change Over
Avoid scrap and defects with flexible control plans that stabilize under varying conditions, allowing teams to adapt seamlessly to changes in demand and resource availability.
Unplanned Stops, Quality Troubleshooting
Pre-emptively correct process behavior before scrap occurs, improving production KPIs.
Production Rate, Cycle Time
Reliably predict difficult-to-measure parameters to ensure faster testing and production cycles.
Quality Tier Level
Reduce the cost of non-quality by up to 50%, optimizing process yield across multiple steps.
Scrap Rate, Defect Occurrence
Reduce defects by up to 40%, while progressing towards prevention of them occurring in the first place.
Reduce Rework
Discover the root cause of latent defects and prescribe optimal process parameter changes to avoid loss in yield.
Small Stops, Setpoint Adjustment
Use prescriptive analytics to make calculated system adjustments for immediate impact on the factory floor.
STOP DEFECTS IN THEIR TRACKS
Find out how much DataProphet’s AI-as-a-Service manufacturing solutions can save you by eliminating shipped defects.
REAL IMPACT FOLLOWS PRE-EMPTIVE ACTION
Real-time information is only useful if you can react in real-time. Yet, for most manufacturers, even real-time is often too late because it is reactive, rather than proactive. DataProphet PRESCRIBE uses prescriptive analytics to recommend changes to the control plan before defects occur.
Most factories use AI solutions to enable better analysis. DataProphet uses AI-as-a-Service to continuously improve your manufacturing processes and operations, so you can:
- Reduce the rate and cost of non-quality
- Achieve stable, consistent production runs
- Close the manufacturing feedback loop
DataProphet’s prescriptions have resulted in a significant reduction in scrap and rework, making a positive impact on our bottom line.
- CEO – Engine Block Manufacturer
AI-GUIDED SCRAP RATE REDUCTION
Move beyond production performance analysis and predictive maintenance – stop defects before they occur with DataProphet’s prescriptive analytics for manufacturing. Our AI eliminates process and technology inefficiencies to bring your plant to its most efficient operating paradigm, and keep it there.
Industries where DataProphet is radically reducing scrap:
- Rubber compounding and curing
- Thermoplastics molding
- Metal extraction and casting
PROCESS OPTIMIZATION AHEAD OF FAULTS
Through continuous machine monitoring and parametric optimization of process behaviors, DataProphet AI-as-a-Service alerts your technicians to real-time faults on the factory floor. It also diagnoses complex failures and prescribes immediate corrective action to prevent defects from occurring down the line.
Prescriptive analytics learn and adapt to real-time data, to continuously improve:
- Machine wear and non-quality costs
- Rework and penalties
- Error diagnosis time
OUR AI-AS-A-SERVICE SCRAPS DEFECTS TO GROW QUALITY
DataProphet’s user-configurable Expert Execution Systems continually diminish scrap and rework. Our world-leading AI mitigates downtime for troubleshooting and instantiates first pass production lines together with greater rolled throughput yield. What does this mean? Your existing and potential customers will gain greater access to more of your high-quality products. Learn how our suite of AI-as-a-Service solutions eliminates defects and supports the development of your manufacturing reputation:
Easy to integrate into existing plant systems
Improved KPIs across entire production line
Prescriptive management of production assets
Guaranteed ROI within 12 months
DATAPROPHET CLIENTS DEFINE THEIR MANUFACTURING QUALITY
In advanced manufacturing, diminishing defect occurrence must - by intelligent design - be bound to increases in First Pass Yield. Quality assurance and capacity growth depend on consistent production runs embedded with reliable KPI monitoring. DataProphet PRESCRIBE can be deployed to discover the fastest production regime and while maintaining quality production performance.
Our client successes include eliminating external automotive scrap, reducing robotic welding defects by 75%, and halving the cost of non-quality – all within six months of implementation.
LATEST ARTICLES AND RESEARCH
Explore how AI and machine learning are transforming manufacturing through increased overall equipment effectiveness and higher product quality.
Automotive Excellence: Quality Welding and Prescriptive AI
15 May 2023
Data-to-value solutions are best navigated with a cross-functional approach integrating different domain expertise. This premium ...
AI Leader Jürgen Grotepass Boosts DataProphet’s Industry Impact
3 May 2023
May 03, 2023 | 17:00 CEST | Nicol Ritchie | • Press releases A NEW ...
AI for Sustainable Automotive Foundries
24 Apr 2023
Digital manufacturing is advancing globally with a focus on sustainability for long-term value. This use ...
Driving Rubber Mixing Process Optimization in the Digital Era
24 Mar 2023
Manufacturers of automotive rubber products grapple with variable input materials. These compound other rubber mixing ...
Setting the Stage for Semiconductor Manufacturing Process Optimization
7 Mar 2023
The modern world relies heavily on semiconductor manufacturing, and the industry is highly competitive and ...
Condals: Process Optimization in Manufacturing Use Case
28 Feb 2023
Across industries, digital-era technologies like artificial intelligence (AI) are proving to be effective tools for ...
Manufacturing Process Optimization in Times of Adversity
7 Feb 2023
Manufacturing process optimization is ever-critical for today’s industrials transitioning into the digital era. These are ...
DataProphet PRESCRIBE Wins 2023 BIG Innovation Award
11 Jan 2023
AMSTERDAM—January 11, 2023—Today, DataPropht announced it had been named a winner in the 2023 BIG ...
DataProphet Named 2022 Winner in the BIG Award for Business
29 Nov 2022
AMSTERDAM—November 29, 2022—Today, DataProphet received the Business Intelligence Group’s BIG Award for Business and was ...
THE INDUSTRIES WE SPECIALISE IN
All DataProphet needs to make an impact on your production floor is data you already have and machines you already own. Explore how we have applied prescriptive analytics in key industries to help our clients continually improve quality and increase production capacity, where necessary, in their manufacturing processes.
AUTOMOTIVE
By actively optimizing control parameters, we helped one German automotive OEM to reduce autonomous welding defects by 75%, contributing to their overall equipment effectiveness.
SEMICONDUCTORS
Chip defects can drastically impact the bottom line and incur high opportunity costs in terms of market share. DataProphet improves chip fabrication and yield to mitigate capital expenditure risk and secure reputational enhancement of fabs.
RUBBER
Dramatically improve the speed and accuracy of rubber manufacturing with DataProphet’s Expert Execution Systems, and set a new standard for high quality, consistently extruded and cured, rubber products.
FOUNDRIES
We consistently achieve a 40% reduction in defect rates within three months at gray iron foundries while finding potential throughput gains.
WHY CHOOSE DATAPROPHET AS YOUR AI PARTNER?
AI-as-a-Service providers often equate research-based methodologies with one-size-fits-all industry solutions. DataProphet partners realize that true AI-driven digital transformation in manufacturing calls for data-backed technology that can be modeled to learn about their unique set of production problems. Partnering with us means guaranteed, continual optimization of your plant state as the first best step towards autonomous manufacturing.
Production Increase
Product Traceability
0% External Scrap
Guaranteed ROI
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