OPTIMIZE YOUR PRODUCTION & ASSETS

From global Fortune 500 companies to small machine shops, manufacturing customers turn to TensorIoT to realize the benefits of smart factory transformations and operational improvements. Whether you want to digitally transform your entire end-to-end manufacturing process or you’re just seeking a purpose-built solution to handle a troublesome issue, TensorIoT can deliver the solution you need.

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Improve situational awaremess

Gain live operational visibility for proactive management

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Reduce unplanned downtime

Keep machinery running and minimize inventory errors

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Increase operating efficiency

Optimize equipment functionality and reduce/lower energy waste

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Address capacity constraints

Maximize asset utilization and streamline scheduling

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Overcome labor shortages

Cut down on manual inspections, automate dirty jobs and support your workers

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Improve product quality

Secure early detection of visual defects and poorly tuned machines

Asset utilization analysis

By deploying SmartInsights, TensorIoT can help manufacturers gain immediate visibility into any variations in the production process. With all key process data visible in a single pane of glass, production team members can easily see anomalies and take immediate action to adjust equipment and the production process. 

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FEATURED CASE STUDY

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GARLAND

For example, after only a few weeks of using SmartInsights, a production engineer at Garland noticed unusual energy consumption in one part of their roofing manufacturing process, indicating a sub-optimal mixing process and an unnecessarily long production time. By adjusting the configuration of the mixing tank drive system, energy consumption was reduced by 15%, throughput was increased by 17%, and the risk of producing defective product was reduced. 

Operational Insights

If you can’t measure it, you can’t manage it. Gaining greater operational insight is a challenge for many firms, due to the variety and vintage of equipment used in production. Industrial assets generally have very long capital replacement cycles measured in decades, whereas technology advances at a pace measured in months and years. Despite the challenges, the benefits to bridging the OT/IT gap include broader observability of assets, increased situational awareness, and deeper insight into maintaining and improving operational performance. There is much to be gained from having key operational data, down to the individual machine and sensor level, all in one place, so your people can be aware of the state of your operation, recognize issues, and more quickly take corrective action.

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FEATURED CASE STUDY

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MULTINATIONAL PRODUCER OF CONSTRUCTION AGGREGATES

Using SmartInsights, a construction aggregates company and its production team members were immediately able to see, for example, running time, crusher utilization, load levels, conveyor speeds, and many other important details. Simultaneously, corporate personnel were able to identify late production starts, compare performance against defined targets, and see overall trends in operating efficiency. SmartInsights also provided alerts and notifications so that on-site employees could respond quickly to issues before they became critical, completely transforming the old break-fix approach.

Real-time visibility, from anywhere

When equipment is deployed at remote locations--your own or your customers’--you want to ensure peak performance. Understanding how machines and other products are actually used in the field can help identify opportunities to reduce downtime and both warranty and non-warranty service costs, understand use cases and identify gaps in documentation and training material, improve customer service, and provide feedback to improve future product designs. Remote connectivity can also enable new business models such as “equipment as a service” where customers pay for work performed by, rather than ownership of, machines and other industrial equipment. Companies from industrial machine makers to home appliance manufacturers have turned to TensorIoT to make things “phone home” and share performance and usage data for a variety of opportunities from performance tuning to pay-per-use business models.

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FEATURED CASE STUDY

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LEADING GLOBAL MACHINE MAKER

To help its downstream customers operate machines as efficiently as possible, a global machine maker engaged TensorIoT to deploy SmartInsights, powered by AWS, to ingest, visualize, and analyze production data, including automated product quality testing data, and make it immediately available to authorized users anywhere in the world. Now its customers can operate its machines with greater confidence and produce higher quality end products.

Defect detection

Manually inspecting raw materials, work-in-progress, and finished goods for defects during the manufacturing production cycle is labor-intensive and prone to errors. It’s critical to detect defects at the earliest possible point in production, before additional value-adding work is performed. Human quality inspectors can subjectively differ in identifying defects, and often fatigue toward the end of their production shifts. Automation can improve production quality by detecting errors quickly and consistently. TensorIoT combines computer vision with modern machine learning to spot defects. By also incorporating machine telemetry data, the identification of root causes of quality issues can be greatly simplified.

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FEATURED CASE STUDY

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LEADING PRODUCER OF SURGICAL IMPLANTS

To help its downstream customers operate machines as efficiently as possible, a global machine maker engaged TensorIoT to deploy SmartInsights, powered by AWS, to ingest, visualize, and analyze production data, including automated product quality testing data, and make it immediately available to authorized users anywhere in the world. Now its customers can operate its machines with greater confidence and produce higher quality end products.