Applications of Big Data

& Advanced Analytics

(In Manufacturing Industries)

Sukanta K Padhy
 Flow of my presentation
• Context setting : My understanding on Big
Data Analytics

• What are the Potential Use Cases in

Manufacturing

• Some case studies

Context setting : My understanding
on Big Data.
 What is Big Data
• Big data analytics is the often complex
process of examining large and varied data
sets -- or big data -- to uncover information
including hidden patterns, unknown
correlations, market trends and customer
preferences that can help organizations
make informed business decisions.
What is Big Data
 What are the enablers
• Ease of Data acquisition (real time ,massive
volumes)
• Mobile technology
• Sensors (IOT)
• Social media
• Ease of Integration / Interoperability

• AI /ML algorithms
 Use cases in Manufacturing
Analytics Maintenance Operations Quality
• .
Descriptive 1. Equipment Monitoring 1. Operations Monitoring 1. Quality Monitoring
2. Performance Analytics 2. Operator behaviour 2. Detect Quality Loss
3. Failure Root Cause Analysis 3. Defect Root Cause
(Insights on Analysis 3. Failure Root Cause Analysis
the present) Analysis

Predictive 1. Predictive Maintenance 1. Predict operation times 1. Predict Quality Yield

2. Predict Production KPIs 2. Early detection of
3. Forecast Demand defects
(A view of 4. Predict Supply Chain
the future) disruptions ( risks)

Prescriptive 1. Reduce Failure Optimise Production, Recommendation

rates & costs Costs, Quality & of all input
(Recommen 2. Optimise Environment variables ( man,
d best Maintenance machine, method)
action) for optimum
quality level
 Some case studies in Tire Manufacturing

• Case study 1 : Optimized Production Routing

• Case study 2 : Predictive Maintenance of Tools

 Tire Manufacturing Process - Curing

• 10 different types of components are manufactured

Component
Making

• All the components are assembled in a Building Machine

Building • Green Tyre is the output

• GT is cured in a Press

• Output is the finished Tyre

Curing
 Curing Operation Detail

• The GT is cured in a Press (High Pressure steam)

– Heating & Cooling cycle is a critical to the process
– Cycle is PLC controlled
– Shape is given to the GT by a mould

• The quality of the finished tyre is visually

inspected
– common defects are surface discontinuities
System Architecture - MES
 Data Captured by the MES

– Operator details ( Skill levels, Past performance)

– Machine details ( which press , history )
– Input material details ( genealogy of the input)
– Tool details ( which mould & its history)
– Process parameter details ( Time , temp & pressure)
– Inspection results of the individual output
 Case study 1 : Optimized Production Routing

 Problem definition : High scrap rates ( about 5%) for the

finished tyres

 Preliminary Hypothesis :
 Quality & workmanship of the GT is critical
 Scheduling on the right press types gives a better control on heating &
cooling cycle for a set of products

 Complexity of the data

 Total number of SKUs produced in a month is around 600
 Total no of Presses is 300
 On an average a SKU can be produced in 25 presses
 A GT can be produced in 10 TBMs ( on an average)
 A total of 5000 tyres are manufactured daily
 Case study 1 : Optimized Production Routing

SKU Serial No Press Id TBM Id Inspection Results

XYZ 1P1 B1 OK
2P2 B1 OK
3P2 B2 Scrap

ABC 1P2 B2 Scrap

2P3 B2 OK
3P3 B3 OK
 Case study 1 : Optimized Production Routing

 Recommendations
 A cluster of presses found to be found to have optimum
level of Yield for a group of SKUs
 Some TBMs are found to be not suitable at all – taken out
of production
 Some moulds are found to have high level of scrap
irrespective of Presses & TBM combinations

Product Group SKU Press Group Press Ids TBMs Moulds

X SKU1 65'' Dome P1, P2 B1 M1 , M2
SKU2
SKU3
 Case study 1 : Optimized Production Routing

 Expected Impact
 Improve Yield to 98.5%
Case study 2: Predictive Maintenance of Tools (Moulds)

 Problem definition
 Moulds are cleaned (insitu & Ice blasting) based on
certain frequency and inspection
 Unexpected downtimes impacting OTD
 Un-necessary downtimes impacting maintenance
costs and productivity.
Case study 2: Predictive Maintenance of Tools (Moulds)

 Solution used
 Predictive Analytics
 Historical production, quality & Maintenance data used at
individual mould level
 Predict types of cleaning required ( insitu & ice blasting)
well inadvance

 Expected Impact
 Reduction in unplanned downtimes by 50%
THANK YOU