Mariner > Case Studies > How AI is Transforming Manufacturing

How AI is Transforming Manufacturing

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 How AI is Transforming Manufacturing - IoT ONE Case Study
Technology Category
  • Analytics & Modeling - Machine Learning
Applicable Industries
  • Automotive
Applicable Functions
  • Discrete Manufacturing
Use Cases
  • Factory Operations Visibility & Intelligence
  • Software Design & Engineering Services
The Customer
About The Customer

Global Chemical & Textiles Company.

The Challenge

Allowing defects to escape the factory damages customer relations and the brand, and leads to costly rejects or returns, while overcontrolling for defects internally leads to high labor, scrap, and rework costs. The pernicious problem of defect detection was supposed to be solved by machine vision inspection, but in many instances machine vision systems are not up to the task.

  • No condition monitoring on valves & motors.
  • Root cause analysis on failed equipment was difficult or nonexistent.
  • Engineers spend hours per week producing spreadsheets and analytics.
The Solution

Deployed AI for machine vision in the manufacturing plants. Ingests BoMs, engineering drawings, and parts specs to generate an understanding of what a complicated assembly should look like – and then watches the article on the line to make sure that assembly is correct at each station.

Operational Impact
  • [Process Optimization - Real Time Monitoring]

    Alerting/Monitoring when detecting emergent conditions sooner rather than later.

  • [Process Optimization - Predictive Maintenance]

    Predictive maintenance reduces unplanned downtime by predicting the probability of failures that impact operations

Quantitative Benefit
  • 97.7% ResNet accuracy - classification accuracy on held-out test set.

  • 30X false rejects reduction.

  • 2-5X improvement over manual Inspection.

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