Real-Time Predictive Analytics in Manufacturing

Vivek A. Ganesan, Principal Architect Yue Cathy Chang, Sr. Director, Business Development

Impetus Technologies, Inc.

Big Data in Manufacturing

The Future of Manufacturing

INTELLIGENT DATA DRIVEN MANUFACTURING

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

More Data, Better Quality
Quality of Management Decisions

Intuition
Amount of Data Analyzed

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

More Data, Better Quality
Quality of Management Decisions

Relevant

Data

Intuition
Amount of Data Analyzed

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

More Data, Better Quality
Quality of Management Decisions

Accurate

Big Data

Relevant

Data

Intuition
Amount of Data Analyzed

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

More Data, Better Quality
Quality of Management Decisions
Quick?

Accurate

Big Data

Relevant

Data

Intuition
Amount of Data Analyzed

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

We Have a Big Data Situation
When traditional information systems cannot …

Store Process Analyze

Volume Velocity Variety

COST TIME

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Big Data in Manufacturing
Volume

• Sensors • Machine data • “Internet of Things”

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Big Data in Manufacturing
Volume Velocity
• Drinking from the fire hose! • Consume or collapse!! • Analyze at the speed of data?

• Sensors • Machine data • “Internet of Things”

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Big Data in Manufacturing
Volume Velocity
• Drinking from the fire hose! • Consume or collapse!! • Analyze at the speed of data?

Variety
• Dealing with diagnostics

• Sensors • Machine data • “Internet of Things”

• Binary data + log data
• Ability to analyze variety of data formats

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Where is the Value in Big Data?

Big Data and the Fourth „V‟
 The fourth „V‟ is „Value‟

 The Value of Big Data in manufacturing is in Analytics
 Gartner defines four kinds of Analytics  Descriptive  Diagnostic  Predictive  Prescriptive
   

What? Who? How? Why? What if? Why not? Who else? What will happen when? What can I do about it?

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Big Data Predictive Analytics
The formula is simple:

1. Collect data at every stage of the manufacturing process
2. Store data on a Big Data store
• Economical, Accessible, Distributed, and Scalable

3. Process data
• Manage the variety and complexity of the data

4. Analyze data
• Apply mathematical models to make predictions

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Predictive Analytics Context
Instruments
D A T A I N G E S T Model
• • • • • Represent Learn Predict Iterate Improve

Predictions
• • • • • •

Control
Fix Throttle Alert Adjust Optimize Abort

 Batch  Historical  Iterative

Analytics

 Real-Time
 Immediate  Instantaneous

Sensors

Feedback

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Big Data, Big Value
 In manufacturing, the greatest value is in :

 Real-Time Predictive Analytics
 Prescriptive Analytics is possible but depends on :
 Good Predictions  Fast Feedback Loop

 Real-Time Predictive Analytics is the first step towards :

 Intelligent Data-driven Manufacturing

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Manufacturing Analytics Quadrant
REAL TIME

BATCH

 Historical  "What happened"  Hindsight

DIAGNOSTIC

PREDICTIVE

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Manufacturing Analytics Quadrant
REAL TIME

 Near-term  "What is happening"  Insight

BATCH

 Historical  "What happened"  Hindsight

DIAGNOSTIC

PREDICTIVE

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Manufacturing Analytics Quadrant
REAL TIME

 Near-term  "What is happening"  Insight

BATCH

 Historical  "What happened"  Hindsight

 Inferential  "What may happen"  Foresight

DIAGNOSTIC

PREDICTIVE

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Manufacturing Analytics Quadrant
REAL TIME

 Near-term  "What is happening"  Insight

 Influential  "Make it happen"  Intelligent

BATCH

 Historical  "What happened"  Hindsight

 Inferential  "What may happen"  Foresight

DIAGNOSTIC

PREDICTIVE

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Opportunities and Challenges
Business Opportunities
• Preventive Maintenance
• Real-time/near real-time actionable response

Technical Challenges
• High Ingestion Rates
• Sensor/tool data with subsecond ingestion requirements • Millions of writes per second

• Improve Productivity/Margins
• Reduce wastes, improve efficiency • Improve Yield

• Complex Log Formats
• Semi-structured data

• Supply Chain
• Optimize supply chain

• Huge Amount of Data
• TB/PB of data storage for deeper analytics

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Let's Get Real!

Real-Time Predictive Architecture

Machine Data

NoSQL + Search

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Real-Time Predictive Architecture

Machine Data

NoSQL + Search

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Input Data: Raw Logs
• Meta-data about the prospective product line is created at a factory site.
– E.g., number of sensors emitting log files or readings.

• Various log files are generated:
– Containing Text. – Containing specific Sensor readings, continuous as well as binary values. – At each time-step, a specific pass/fail.

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Input Data: Parsing
This data is parsed into a matrix representation • Columns representing sensor logs • Rows representing the time In our dataset: • 590 attributes, approximately every minute
– Missing Data from logs

Machine 1, sensor 1-120

Machine 12, sensor 1-92

• Also has labels: {+1,-1} for failure/success from for each time-step • 50,000 time-steps, i.e., 29.5 million values (“parsed”, not raw) in a month
© 2013 Impetus Technologies

Time

– Failure : success :: 1 : 15

Interactive Visualization

Misalignment

Yield: 85% Failure < 1%

© 2013 Impetus Technologies

Time: 12:00

Interactive Visualization
Machine 4, Tool 3, 4. Input from Machine 2.

Misalignment

Yield: 86% Failure < 2%

© 2013 Impetus Technologies

Time: 12:01

Interactive Visualization

Misalignment

Yield: 81% Failure < 3%

© 2013 Impetus Technologies

Time: 12:02

Interactive Visualization

Misalignment 30%

Alert: Machine 2, Tool 3, 12, 14 are not nominal

70%

© 2013 Impetus Technologies

Time: 12:03

Interactive Visualization

Misalignment

Alert: Machine 2, Tool 3, 12, 14 are not nominal

90%

© 2013 Impetus Technologies

Time: 12:04

Interactive Visualization
Alert: Machine 8 and machine 4 are failing. Cause: Machine 2 has voltage imbalance

Misalignment

© 2013 Impetus Technologies

Time: 12:05

Interactive Visualization
90% Misalignment
Alert: Machine 8 and machine 4 are failing. Cause: Machine 2 has voltage imbalance

80%

© 2013 Impetus Technologies

Time: 12:05

Interactive Visualization
90% Misalignment
Alert: Machine 8 and machine 4 are failing. Cause: Machine 2 has voltage imbalance

80%

© 2013 Impetus Technologies

Time: 12:05

Key Takeaways

• • • •

Measure and Collect Everything Process, Diagnose, and Predict Get Real with Real-Time Generate Actionable Intelligence

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Talk to us about Impetus Solutions and Services for Manufacturing Big Data
Assessment Objectives & Strategy Model BUSINESS PROCESS MANAGEMENT Analyze & Optimize People, Process, Technology Impact Solution Analysis Solution Modeling

Business Analytics and Data Science

Solution Architecture, POC and Production planning

Technology strategy, Use Case development & Validation

bigdata@impetus.com
Big Data Platform Implementation

bigdata.impetus.com

Operations and Visualization

© 2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/
For more Info contact bigdata@impetus.com

Thank You

bigdata@impetus.com bigdata.impetus.com Recorded version available at http://lf1.me/hqb/

© 2013 Impetus Technologies

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