Maximize process efficiencies across manufacturing facilities to minimize waste; enhance resource and energy economy; optimize yield, and reduce your footprint.
More than ever, perceived value in advanced manufacturing is coupled with real-world low environmental impact. As verticals move towards Industry 4.0, inefficient resource management on production lines – to do with material waste and excessive energy expenditure – is doubly injurious to competitive advantage. Why? Because industrial sustainability standards often presuppose the uptake of new, more efficient, manufacturing technologies. DataProphet’s AI-as-a-Service solutions for complex, energy-intensive manufacturing processes are designed with the ecological imperatives of global plant efficiency – and their associated financial pressures – in mind.
DataProphet PRESCRIBE’s deep learning algorithms zero in on only the modifiable manufacturing behaviors relevant to process optimization on your existing production line. This means PRESCRIBE can benchmark quality and throughput metrics that contribute to the ongoing stabilized efficiency of production lines, without capital expenditure on new technologies, or restructuring.
DataProphet’s AI solutions for manufacturing detect performance anomalies ahead of defects occurring on the production line so that you can act before scrap occurs. Our prescriptive analytics solutions also find the optimal chemical and raw material recipes to minimize waste, maximize resource efficiency, and keep the production line running optimally.
Our AI drives pre-emptive changes to correct unit process behavior up and down the line before scrap occurs, reducing the cost of non-quality, and effecting a defect reduction of up to 40%.
Dataprophet’s prescriptive analytics reveal hidden energy waste in control plan design, leading to reduced consumption with an equivalent improvement in KPI benchmarking.
Because PRESCRIBE parses all historical defect data and discovers the root cause of latent defects, it can guide optimal process parameter changes to minimize rework.
Our contextualized API-as-a-Service solutions are conducive to improvements in continuous processes where overprocessing is common. Ongoing pre-emptive setpoint adjustments target inefficiencies in filtering processes to guard against final product yield being lost in material by-products.
Our pre-emptive analytics continually learn, adapt, and prescribe optimization for industrial processes to ensure energy efficiency, minimum waste, and mutual reinforcement of quality and yield across your entire production line. Find out how much DataProphet can save you in waste management costs.
Effective waste management is a key feature of a successful manufacturing operation. Supporting faster root cause analysis of process parameter drift across key manufacturing verticals, DataProphet’s suite of deep learning AI solutions can increase First Pass Yield or Rolled Throughput Yield while improving global plant resource efficiency.
DataProphet AI-as-a-Service helps you better manage resources and production waste by:
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
High-speed hollow glass forming is prone to interruption for machine maintenance, cost-intensive troubleshooting of process deviation, and excessive scrap. DataProphet PRESCRIBE learns optimal ranges for the targeted controllable parameters, and adaptively applies the ideal setpoints to sustain optimal production performance for melting furnaces, individual section machines, and annealing.
Tire manufacturers test rigorously for balance, vibration, and deformation because tire vulcanization is liable to obscure tread, belt, bead and sidewall failures that will only manifest during an inspection. Scrapping anomalous tires which fail to meet increasingly high-performance standards is costly and disruptive. DataProphet PRESCRIBE continually discovers key controllable temperature and pressure profiles optimal for tire curing, thus ensuring ongoing recipe refinement to reduce scrap and significantly mitigate ecological liability risk.
Explore how to continually improve root cause fault analysis; pre-empt and avoid defects to reduce scrap; optimize production lines to mitigate waste; increase throughput and exceed quality targets in tandem, and project global plant efficiencies ahead of real-time. Our Expert Executions Systems will ensure your production assets are deployed to deliver maximum value to customers with minimum waste.
Our Expert Execution Systems have achieved real, sustainable advantages for material processing manufacturers of aluminum, steel, metal casting, and glass. DataProphet PRESCRIBE also excels in any industrial production context where deep learning of controllable and non-controllable process variables adds value.
For this reason, our AI is equally suited to the mineral and precious metal industries where overprocessing and excess waste present constant threats to resource efficiency and bottom line. Our prescriptive analytics learn and optimize benefaction in filtering processes to continually lower disposable waste, and to reduce the loss of the valuable material during separation.
DataProphet 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.
Explore how AI-driven solutions and machine learning are transforming advanced manufacturing with ongoing improvements in production KPI benchmarking.
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DataProphet positively impacts waste management for manufacturers using their existing data and the machines they already own. Explore how we have applied our prescriptive analytics in key industries to help our clients gain continuous production process efficiencies.
By actively optimizing control parameters, we helped one German automotive OEM to reduce autonomous welding defects by 75%, thus reducing rework and parts waste.
Hidden process anomalies during solder paste printing and reflow cycles mean avoidable waste for semiconductor device makers. DataProphet improves chip fabrication quality and yield.
DataProphet’s Expert Execution Systems have affected significant and ongoing improvements in the speed and accuracy of rubber manufacturing for reduced scrap and better waste management.
We have consistently improved global plant efficiencies by achieving a 40% reduction in defect rates within three months at gray iron foundries.
Partnering with DataProphet guarantees lean manufacturing in a shared journey towards Industry 4.0. Our AI-driven solutions trace product and machine data to leverage all relevant process interactions, then model actionable steps to minimize defects via optimal, continually updated control plans. Our clients have discovered the best first step to autonomous manufacturing includes reduced waste and better resource management.
Stay up to date on machine learning developments, plus guidance on how to optimize your manufacturing processes using AI.