A leading global food manufacturing company was faced with productivity issues from unplanned downtime and lack of operational visibility. Visionaize was tasked with not only implementing the right solutions for enhancing the productivity and efficiency of the production lines but also with helping correct unexplainable production interruptions.

Using Predictive Maintenance, Advanced Analytics and Machine Learning, Visionaize developed a solution that would identify failure and reliability issues before they occurred. The solution diagnosed the faulty equipment and by uncovering the root cause and providing recommended actions, Visionaize enabled the operator to take quick and valuable plant floor level decisions.

• Reduced unplanned downtime by 17% Reduced unplanned downtime by 17%
• Reduced energy consumption by 2.5%
• Improved OEE by over 15% by avoiding downtime

A leading manufacturer of metal parts was experiencing difficulty tracking downtime, leading to poor machine performance, unclear operating procedures, and production bottlenecks. A digital twin pilot focusing on machine health analysis was run to optimize throughput and equipment utilization and provide visibility into the benefits of potential maintenance policies, in various scenarios.

The machine health digital twin was able to provide actionable recommendations for users by monitoring machine conditions, visualizing machine effectiveness data, validating and updating machine process schedules and scheduling machine maintenance. Additionally, Engineers were able to troubleshoot equipment remotely, reducing time to resolution and time needed at the facility.

• A 25-30% increase in OEE
• $84K increase in revenue generated per machine
• 30% increase in machine utilization

One of the largest global steel conglomerates in the world had needs to reduce costs, maintain efficiencies and improve product development. Temperature variations were a challenge that affected product quality and contributed to unnecessary downtime. Reducing costs, maintaining safety standards, and aligning divisional and corporate needs were also important needs.

Visionaize identified opportunities for IIoT-based digital strategies and major improvements included display of real- time operational information, data aggregation from disparate sources, monitoring of consumption and sustainability KPIs and alerts for sudden changes in usage patterns. Forecasting and planning based on near real-time reporting was also carried out.

• Off-spec oven temperature reduced by 4%
• Gas consumption reduction of 2%
• Total savings of $120k USD/year