OPTIMIZE ENERGY-INTENSIVE MANUFACTURING OPERATIONS
Targeted Energy Optimization
Efficiencies gained through process optimization naturally result in energy savings across the production line. Yet, often reducing energy costs is a target on its own. When specifically applied to reduce energy consumption, AI-driven process optimization is a powerful tool. It uncovers hidden power drains in your control plan and defines new production parameters to reduce consumption and improve global operating performance. DataProphet CONNECT captures and digitizes historical and real-time production data, which DataProphet PRESCRIBE uses to find the process parameters that result in the lowest energy usage.
ADAPTIVE AI DRIVES ECO-EFFICIENT MANUFACTURING
For manufacturers, intelligently harnessed prescriptive machine learning means continual improvements in industrial energy efficiency. DataProphet PRESCRIBE aggregates all changeable process parameters pertinent to a specific production line.
Our deep learning algorithms recognise the dynamic state of your plant from its process data history, and glean whether the actual process is within ideal operating ranges.
Depending on what metrics PRESCRIBE has been trained to improve, this can include the variables that underlie energy intensity and consumption. DataProphet PRESCRIBE then guides operators, process engineers, and technicians to make parametric adjustments to ensure continued energy efficiency during production ahead of real-time.
Cost Savings
For some manufacturing processes, energy consumption is one of the main drivers of production cost, and any energy savings positively impact the plant’s performance.
Reduction of Overprocessing
In lean manufacturing, one form of waste to be eliminated derives from overprocessing when additional cycles and/or increased processing intensity do not yield additional value to the final product.
Emissions Reduction
By reducing energy consumption, all factories mitigate their carbon emissions, supporting the global effort to comply with increasingly stringent environmental regulations.
Extension of Equipment Life Cycles
In certain manufacturing processes, reducing operational energy intensity and optimizing energy consumption contributes to the lifespan of industrial assets.
REDUCE ENERGY CONSUMPTION WITH MACHINE LEARNING
Find out how much DataProphet can save you in direct and indirect energy costs.
INDIRECT ENERGY SAVINGS
Energy savings are often secondary to optimizing other production parameters, such as quality, throughput, and scrap reduction. DataProphet DETECT ingests data from existing machines, systems, and processes, helping you achieve indirect energy savings through reduced machine downtime, optimal machine use, and minimal impact on upstream and downstream processes.
REDUCE SCRAP, SAVE ENERGY
There is an additional wasted energy cost for every item you scrap, not to mention the extra energy needed for rework and the time wasted finding the right machine setpoints. DataProphet PRESCRIBE finds the optimal recipe across production parameters to maximize the energy efficiency of your processes. This way, manufacturers use as little energy as possible to achieve the desired product quality.
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
POWER-UP AI IN MANUFACTURING
Through continuous machine monitoring and parameter optimization, DataProphet AI-as-a-Service diagnoses complex failures and prescribes immediate corrective action to prevent down-the-line defects.
With DataProphet PRESCRIBE, you can:
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- Optimize energy consumption costs in hollow-glass forming
- Reduce overprocessing and waste/energy liability in materials processing industries
- Expend less energy in first-pass extrusion and injection molding processes
- Gain eco-efficiency in aluminum and steel rolling
CYCLE TIME REDUCTION
Longer process cycle times use more energy. Optimizing the time that it takes to achieve a “first time pass” can significantly reduce your variable energy consumption and costs. Together with the suggested optimal operational parameters, DataProphet PRESCRIBE reduces expensive stops on the line through increased asset uptime and enhanced overall equipment effectiveness.
DEEP LEARNING STREAMLINES MANUFACTURING ENERGY
Explore how deep learning, pre-emptive analytics can help you identify root causes of energy waste, and prescribe optimal parameters for ideal energy efficiency on your production line. All while reducing scrap and eliminating the cost of non-quality ahead of real-time.
Easy to integrate into existing plant systems
Improved KPIs across entire production line
Prescriptive management of production assets
Guaranteed ROI within 12 months
OUR CLIENTS ARE LEADING THE TRANSFORMATION OF MANUFACTURING
Our client successes include eliminating external automotive scrap, reducing mechanical welding defects by 75%, and halving the cost of non-quality – all within six months of implementation. Get results, fast.
LATEST ARTICLES AND RESEARCH
Explore how prescriptive analytics is transforming manufacturing through optimized energy consumption, 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
Our robust, deep learning solutions can target underlying energy consumption process variables specific to different manufacturing verticals.
AUTOMOTIVE
By actively optimizing control parameters, we helped one German automotive OEM reduce autonomous welding defects by 75%, rendering their rate of energy consumption throughout the line more economical.
SEMICONDUCTORS
In high-tech, high-risk enterprises, systemic manufacturing defects translate into serious production energy loss. DataProphet improves chip fabrication, so semiconductor manufacturers gain full value from priceless yield ramps.
RUBBER
Improving the speed and first-pass rate of defect-prone rubber manufacturing with DataProphet’s Expert Execution Systems means eco-efficient production.
FOUNDRIES
We have consistently achieved a 40% reduction in defect rates within three months at gray iron foundries, a highly energy-intensive vertical that prizes first pass production.
WHY CHOOSE DATAPROPHET AS YOUR AI PARTNER?
More than ever, competitive advantage in complex, multistep manufacturing means responsible consumption and eco-efficient production must be embedded in digital transformation. By partnering with DataProphet, you can leverage our Expert Execution Systems to step towards energy-economical autonomous manufacturing. Our partners embrace Industry 4.0. and become world-leading innovators in adopting AI-as-a-Service for sustainable manufacturing.
Production Increase
Product Traceability
0% External Scrap
Guaranteed ROI
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