Use Cases

IG Petro, Tata Steel, Mahindra,

ITC, Titan, ABB, Airbus

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 Snapshot of Neewee Use Cases / References
Why the need What was done What outcomes were delivered How root causes were identified leading to predictions and recommendations
How was it measured

Industry Customer Context / Issues by Neewee's Bodhee Impact 1 - Data Acquisition 2 - Process Twin 3 - A.I. Recommendations

DISCRETE

Prediction of +20% in work closure;

Aerospace AIRBUS Process bottlenecks, lead times Yield + Quality From existing DataLake Real-time monitoring Variability, Deviations
quality gate behaviour +15% in quality gate pass

Direct test Machine connectivity,

Automotive MAHINDRA Field Failures, Rework Prediction engine Failures Quality +18% quality Optimization of Thresholds Testing critical parameters
Offline engine data upload

Electrical ABB Bottlenecks Improvement of first pass yield First pass yield improvement 25% PLCs as well as other IT Systems Process Deviation and Alerts Root Causes, Traceability

Watches TITAN Deviations, bottlenecks, rework Prediction of Process Outcomes Rework reduction 10% cost reduction Install acquisition systems Process Deviations Variability

PROCESSS

Prediction on outcomes in
Impact on outcomes due to Matrikon and SAP systems, KPI Reporting and Dashboards, Optimal RM combination, Trend
Steel TATA STEEL relation to variations due to Cost Reduction Being measured
raw material variability Manual Input screens Process Deviations and Alerts Analysis and Dashboards, Correlation
Raw material composition
Recommendation of process
Matrikon and SAP systems,
Steel TATA STEEL Low Yield parametres for optimized Productivity Improvement Being measured Process parameters Productivity, Simulation
Manual Input screens
process run

Recommend a system 91% reduction Variability, Deviations,

Agro ITC Moisture deviation, Yield, Quality Yield + Quality From OPC servers and PLCs Process deviations
for moisture control in standard deviation Direct machine controls

Shorter production run, Increased Recommendations for Yield Improvement + 2 Cycles per Month Golden composition,
PetroChem IGPL SQL Servers Process Deviation and Alerts
energy cost, low productivity extending dehydration run Cost Reduction Reduction parameter identification
Unplanned downtime, Failure prediction Yield Improvement +
PetroChem IGPL Being measured SQL Servers Process Deviation and Alerts Run time optimal Parameter
Increased cost for steam turbine Cost Reduction

Full details available at: https://app.box.com/v/neewee-use-cases 2

Case Study:
Prediction of
Quality Gate Behavior

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 Case Study | Aerospace
Business Problem Objective
• Predictability on the Outstanding Work and Quality Issues Implement a system which can reduce lead times
• Low Visibility on bottlenecks
• No Early warning Alerts for remedial actions • Perform predictions at each work station and
product level at each of the stage
• Impact on Yield and Quality
• Clear actions on work orders and tasks
• Bottleneck identifications
• Early Warning Alerts
Use Cases Delivered
Data Acquisition Connected Processes & Improvement Opportunities Impact
Machines
Data Acquisition Mechanism • Creation of Process Digital • Potential impacts of • Yield Optimization
from enterprise data lake Twin variability, deviations and • Quality Improvements
• Production Line Modeling suggested corrective actions
• Real Time Production • Root Causes and patterns
Monitoring • Reduction of Bottlenecks
• Process Deviations

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Case Study | Aerospace

Implementation Timelines
8 Weeks Per line

Impact Metrics

20% 15%
Work Closure Rate QG Pass Rate
Improvement Improvement

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Case Study | Aerospace

19 lines

16 lines

10 lines

1 line

Component Final Assembly Plant_3

Pilot in Plant_A Industrialization in Industrialization Implementation Discussion on for
(Country 1) Plant_A (Country (Plant_A + Plant_B starts in 3rd other plants
1) in 2nd country) country

June 2017 Aug 2018 Apr 2019 Oct 2019

The First major Across 10 lines in the 6 additional Lines 3 additional Lines
Breakthrough plant across 2 plants

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Call to Action

Airbus invites
strategic supply
chain partners to
leverage Neewee’s
industrial analytics
10 March 2020, Toulouse, France

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8
Case Study:
Recommendations for
extending for
Dehydration run

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Case Study | Chemical
Business Problem Objective
• Due to upstream variability, wash water content keeps • Identification of Golden Combination of wash
changing causing variable foul generation during each run water composition and parameter setting

• Though foul creation is part of chemical process, there are
frequent cases where production needs to be stopped and
wash of dehydration column needs to be performed
• Each wash taken up 8-10 hours of production time thus
impacting Productivity, Yield and Costs
• Improvement of Productivity/Yield by reducing
the number of washes
• Run time optimal Parameter Recommendations
to ensure right for extending the current
execution

Use Cases Delivered

Data Acquisition Connected Processes &
Machines
Data Acquisition Mechanism • Creation of Process Digital
from SQL Servers Twin
• Process Deviation and Alerts
Improvement Opportunities Impact
• Golden composition and • Yield Improvement
parameter identification
• Prediction of duration for the
current run
• Recommendations of optimal
parameters for extended run

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 Case Study | Chemical

Implementation Timelines
Predicted Run Duration
Golden Composition 8 Weeks

Impact Metrics

7 5
Cycles per month Cycles per month

*Numbers are illustrative

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Case Study:
Failure prediction
for steam turbine

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Case Study | Predictive Maintenance
Business Problem Objective
• Difficult to anticipate issues primarily due to: • Predictive system for nuanced early warning alerts
for cost considerations
• Though real time alerts are available for some patterns, gradual
deterioration is not detected leading to sudden failures • Detection of early onset of behaviour change for
• Large no. of parameters which determine the performance which better procurement planning of spares
interact non-linearly
• Forecasting of critical parameters for quicker actions
• Patterns are not captured which lead to failures
• Early Warning Alerts are not available and hence response is reactive
rather than proactive
• High Preventive Maintenance Costs

Use Cases Delivered

Data Acquisition
Data Acquisition
Mechanism from SQL
Servers
Connected Processes &
Machines
• Creation of Process Digital
Twin
• Process Deviation and Alerts
Improvement Opportunities Impact
• Identification of sudden and gradual • Cost Reduction
changes for critical parameters
• Forecasting for failures
• Nuanced early warning alerts
• Detection of behavior changes for the
asset components

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 Case Study | Chemical
Current Values Predicted
Parameter
Values
Implementation Timelines
8 Weeks

Impact Metrics

Base Week Selected Comparison Week

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Case Study:
Predictions on Outcomes
in relation to variation
due to
raw material composition

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Case Study | Iron Ore De-oxygenation
Business Problem Objective
• For the DRI lines, though the data is getting collected from • Creation of Process Digital Twin ( Visual as well
the process real-time, its not getting stored for analysis to as Process Modelled)
• Low information on co-relation between RM, Yield and Costs • Trend Analysis and Dashboards
• Optimal parameter setting for each combination of RMs • Co-relation between the influencing parameters
• Identify potential productivity improvement opportunities. and the process critical parameters
(Temperature)
• Process being reactive rather than pro-active
• Temperature Differential Analysis, outlier
• Inconsistency in output analysis
• Provide foundation for Simulation abilities

Use Cases Delivered

Data Acquisition
• Data Acquisition Mechanism
Metrikon and SAP systems
• Manual Input screens for
closure of data gaps
Connected Processes &
Machines
• Creation of Process Digital
Twin
• KPI Reporting and Dashboards
• Process Deviations and Alerts
Improvement Opportunities Impact
• Identification of relation between process • Cost Reduction
parameters and Yield • Productivity
• Optimal RM combination Improvement
• Process parameter recommendations for
optimized yield

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Case Study | Iron Ore De-oxygenation
Implementation Timelines
8 Weeks

Impact Metrics

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Case Study | Iron Ore De-oxygenation

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Case Study:
Prediction of
Engine failures

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Case Study | Engine Performance Predictions
Business Problem
• Engine sub-assembly is one of the complex assemblies in
the plant with various sub-process. Each operation within a
sub-process has an impact on the performance of the
engine. But there is
• Limited visibility on relation between various operational
and parameters and Engine performance during hot test as
well as field trials
• No comprehensive knowledge on data co-relations
between parameters and engine failures
• Sub-optimal thresholds for early problem detection
Objective
• Predict the Load testing parameter values (in range) based
on the test results from cold test for each of the pre-
defined RPM values by establishing co-relation between
cold and load testing parameters
• Analysis of the cold testing data as well as patterns leading
to known defects such as engine cease
• Explore the possibility of identification of optimal threshold
bands for critical parameters which can be fed back into the
cold testing machines for better results

Use Cases Delivered

Data Acquisition Connected Processes Improvement Opportunities Impact
& Machines
• Offline engine data • Creation of Process • Identification of relation between cold • Productivity Improvement
upload provision Digital Twin and hot test parameters for better • Cost Reduction
• Direct test Machine understanding of engine behavior • Improved CSAT
connectivity planned • Patterns to identify types of failures
for future phases • Optimization of Thresholds for critical
parameters to catch the defects early

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Case Study:
Prediction
of process outcomes
in watchmaking

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 Case Study | Consumer Products

Business Problem Objective

• Rework on the products Implement a system which can reduce the rework:
• Process Deviations • Flag Process Deviations on the Assembly Lines
• No warning and predictions on the likely issues • Predict the quality issues and reworks
• Low visibility on bottlenecks • Automation of a sub-process
• Dosage to electroplating material cylinder

Use Cases Delivered

Data Acquisition Connected Processes & Improvement Impact
Machines Opportunities
• Implementation of automated data • Creation of Process Digital Potential impacts of Rework Reduction
acquisition systems Twin variability, deviations and
• Interface of HMI/SCADA/PLC/CNC/ MES • Process Deviations suggested corrective actions
systems
• Interfacing OT instrumentation / Sensors /
RFID/ Actuators

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Case Study | Consumer Products

Implementation
Timelines
10 Weeks Per line for
Software Additional 4
weeks for Automation

Impact Metrics

10%
Rework Cost
Reduction

*Numbers are illustrative

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Process Digital Thread
Process Digital Thread for Nickel Electroplating
• Bodhee® traces the journey of cases in a batch from
the loading station all the way to the unloading
station

• Process parameters viz Temperature, Dwell Time, pH

sample, Amp Current Ratings per work-center are
monitored

• Any deviation is highlighted to the operators on the

shop-floor via Tower Lights on each work-center or
through the digital thread in the monitoring center

• Amp Current, Temperature, Dwell Time, process

path are automatically personalized to the Nickel
model being electroplated

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Process Digital Thread

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Process Parameter Control (Machine Control)

Bodhee® interfaces with multiple

manufacturing assets to control the processes
based on the Watch Case model being
electroplated.

Key process parameters personalized to

models are:

1. Amp current being supplied for specific

model electroplated via the Rishee (IoT)
enabled DC rectifiers

2. PLC control to manage the Pumps /

Solenoids and other automation
equipment to skim the surface impurities
in the baths at various stages of
electroplating.

3. Temperature level & centrifugal dryer

dwell time interlocks per model being
electroplated

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Run-Based Maintenance

• To have an optimal throughput,

Bodhee® monitors the work-
center usage and raises alerts
for maintenance

• The early warning helps the

maintenance team plan for the
upcoming tasks and avoid last
minute production loss due to
equipment unavailability

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Bodhee® Landscape

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Case Study:
Improvement of
First Pass Yield

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Case Study | Electrical
Business Problem
• Siloed and disconnected data is preventing the production team from
• Having an ability to identify bottlenecks to improve productivity
• Have an end to end view of production process for traceability
Objective
• Closure of data gaps on in-scope lines by connecting the
siloed machines/data sources
• Inclusion of connected data elements in the KPI reporting
• End to end visibility of the production lines with currently
available data elements
• Pattern identification causing low first pass yield

• Identification of Root Causes and patterns for low first pass rate • Key KPIs Reporting and drill downs

Use Cases Delivered

Data Acquisition
Data Acquisition Mechanism
various machines, PLCs as well as
other IT Systems
Connected Processes &
Machines
• Creation of Process Digital Twin
• Process Deviation and Alerts
Improvement Opportunities
• Patterns causing low pass yield
• Identification of stations
within each machine to be
calibrated
Impact
• Yield Improvement
• Rework and cost reduction
• Productivity improvement

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 Bodhee – What was done?
Automated MCB Line
(Miniature circuit breakers)

Final Assembly Machine –

Product Machine High Small Stops, Impact on
Process
Parameters Parameters downstream Productivity
Parameters

Machines
M1

Productivity
M2 Data Process Product Bottleneck Station Improvement
Integration Digital Digital Identification Profiling • Actionable
Twin Thread Recommendations
• Predictive Alerts

M7

Station Switching & Thermal Rejections

Parameters Machines –. Low First First Pass Yield
Pass, Impact on Yield Ratings

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 Bodhee – How was it done?
Aggregate Data At Pole Code Level Testing Data at Pole ID Level

Pre-Assembly Final-Assembly Switching &

2.1 – 2.3 Machine Thermal Magnetic HV Testing Logo Printing Laser Printing
Machine Calibration Testing Testing

Switching & Calibration Stations Thermal Testing Rejections Thermal Stations

201 202 203 204 205 206 207 No current 101
Process timeout 102
Therical too early 103
Therical too late 104
Therical too late later then T2 105 Interaction between upstream
Voltage too high
106 and downstream process
.
stations impacting First Pass
Yield and Productivity
119
.
1. Station level Profile generation by each Machine .
2. Station performance degradation (Rejections) profiling by Rating 129
3. Switching Station and Thermal Station best and worst scenario modelling by Rating and Pole Code .
.
136 32
 Bodhee – What was accomplished?
Bodhee Recommendation For Rating: 63A, Pole Code: 2CDS201158R4340 Recommendations Trial Results
Switching Stations Thermal Stations
201 Station FPY %
202 119 68% 1. Switching Station 202 and Thermal Station 119 & 129
identified for higher First Pass Yield (~70%)
203 129 74%
2. Switching Station 202 and Thermal Station 121 & 123
204 121 51% identified as bottlenecks with low First Pass Yield (~43%)
205 123 36%
Relative First Pass Yield
206
difference Predicted: ~25%
207

Demo Run Output – 17th September

Switching Stations Thermal Stations
201 Station FPY % First Total
Pass Relative First Pass Yield
202
difference Observed: ~21%
119 71% 35 49
203
129 84% 43 51
204
121 63% 45 71
205
123 64% 44 69
206
207
Ability to identify levers to achieve Optimal Productivity on a continued basis
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 Bodhee – What Next at this manufacturing site?
7 Stations 36 Stations 7 Stations 7 Stations

Pre-Assembly Final-Assembly Switching &

2.1 – 2.3 Machine Thermal Magnetic HV Testing Logo Printing Laser Printing
Machine Calibration
Testing Testing

PLC PLC

SQL Server

Actionable Insights

Predictive Actionable Alerts & Realtime

Recommendations

Operators 34
 Bodhee – What’s Next with this customer?
Driving Productivity Globally
Overall Productivity
Improvement

Automated MCB Line All Global Plants

Nela-----
All Lines
All Divisions

Automated RCCB Line

All India Plants

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Case Study:
Recommend a system
for moisture Control

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Before / After: the impact of Bodhee® on deviation

without Bodhee® With Bodhee®

91%

1.76 Standard Deviation 0.15 Standard Deviation; 91% improvement

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Case Study | Agro
Business Problem Objective
• Maintaining the right level of moisture content of Tobacco is crucial to • Reduction of Standard Deviation against the set-
get optimal yield and desired quality. point
• The right level of moisture varies by raw material quality/grade, it’s • Optimal Steam and Water Usage
current moisture content, ambient temperate, feed rate into the process. Recommendations to ensure right Moisture
• This variability currently handled by changing the settings manually. But Output based on
this has led to • Input Raw Material Quality
• High SD (Standard Deviation) in the output moisture content • Blend
• Low Yield • Season
• Quality Impacts

Use Cases Delivered

Data Acquisition
Data Acquisition
Mechanism from OPC
Servers and PLCs
Connected Processes Improvement Opportunities Impact
& Machines
• Creation of Process • Potential impacts of variability, deviations • Yield Optimization and
Digital Twin and suggested corrective actions Quality Improvement by
• Process Deviations • Direct machine controls based on Bodhee controlling the Standard
Recommendations Deviation of output moisture

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Tobacco manufacturing is challenging
For simplicity intermediate detailed processes
The process of converting raw tobacco leaves have not been depicted
into commercial grade tobacco is quite
complicated.
Leaf Tips Feeds Pre-Conditioning
The leaves are cut into two pieces. The upper
portion is called as Tip and the lower portion … …
is called as Butt. The Butt is removed from
the stem by a process called Threshing. O/P
Primary Conditioner *
Threshing happens in the most optimal way if
the right moisture content is maintained. The
level of moisture varies by type of Tobacco
Leaf Butt Feeds De-sanders
blend, grade, temperature etc.

Tobacco Production falls under the category

of process/continuous manufacturing with
lines having a continuous feed of raw
material for a particular blend.
Maintenance of critical parameters at each
station and predictions/early warnings have
significant impact on quality.
… …
* The Primary conditioner is a large rotating cylinder which is responsible for imparting
the moisture to Tobacco leaves before they are processed further. The requirement of
imparting Moisture on the leaves is dependent on a) the Type of Leaves b) the Blend of
Tobacco to be achieved c) the Temperature

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One must identify the sources of variability in the process

DIFFERENT GROWING DIFF. TEMPERATURE/

DIFFERENT FARMERS DIFF. GROWING SEASONS
REGIONS HUMIDITY/ RAINFALL

Septembe October
r

November

DIFFERENT TRANSPORT DIFFERENT STORAGE DIFFERENT BUYING

AMBIENT CONDITIONS AMBIENT CONDITIONS SEASONS

* High Level Process depictions from customer provided material. Reproduced with Permission 40
Irrespective of Variability, Output needs to be consistent

Stem in Lamina
# Regions = 6 - 2% or less

# Green Grades ~ Particle Size –

270 Thru Quarter (8% or less)

Moisture
# Blends~ 200 – (11.5-12.5%)

HIGHLY VARYING INPUT CONTROLLABLE PROCESS SPECIFIC & CONSISTENT

MATERIAL SETTINGS REQUIREMENT

Maintaining Output Moisture at specified level is the key to achieve the goal

* High Level Process depictions from customer provided material. Reproduced with Permission 41
Measuring the impact of variation on output moisture

Maintaining the right level of

moisture content of Tobacco is
crucial to get optimal yield and
desired quality.
The right level of moisture varies
by raw material quality/grade, it’s
current moisture content, ambient
temperate, feed rate into the
process.

This variability currently handled

by changing the settings manually.
But this has led to
1. High SD (Standard Deviation)
in the output moisture
content
2. Low Yield
3. Quality Impacts
Set Point
The variability in SD is very high and it varies by Blends, Shifts, Season and Skill
Level of Operators.
If SD is reduced, it will have a direct impact on Quality as well as Yield
Note: The numbers shown above have been changed. Intent is to show the essence of problem. But changed
numbers are directionally consistent
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Finding a way out

Supply Chain
Operations
Variation AUTONOMOUS Manufacturing Operations
Raw Material
Quality Issues
Output
Process 6
Moisture
New Products Process 1 Process 3 Process 4
and Variable
specifications Process 7
Process 2

Custom
Products
Manufacturing Speed

External Factors

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Where we need to bring Autonomy to Operations
❑ If the leaf has higher moisture
Moisture
Steam imparted
(than is optimum), it turns
leaf, ready wet and clogs up the thresher
Water creating a down-time
for threshing

❑ If the leaf has lesser moisture,

it generates more scrap (low
economic value) in the
thresher.

❑ An operator stays at the

The objective of the Primary conditioning cylinder is to impart cylinder 24X7 to adjust the
the right moisture and uniformity to the leaves before they go settings in tune to the
into threshing. This is achieved by letting the leaves pass through incoming raw material to
a controlled chamber where steam and water are sprayed in mist ensure that the output
form quality is desired and
consistent
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* High Level Process depictions from customer provided material. Reproduced with Permission
Bodhee: the solution to achieve Autonomous Operations

PC Tablet Smartphone Machine HMI

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The problem can be solved with a process digital twin
• The key is to view the Manufacturing value
chain as a set of sub-processes which are
connected to produce an outcome. This is
needed to capture the variability
• This is followed by the creation of a Process
Digital Twin which will model the variability
with the output produced by the process

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Linking Process Autonomy Objectives with Business Goals

To control the output

Quality , Yield
moisture of tobacco
leaves using Bodhee: Reduction of
Control Output Moisture Standard Deviation
We do this by against the set-point
recommending the
appropriate levels of
steam and water flow
as well as the no. of
valves for the Primary
Optimal Steam and
Conditioner. Predictions and Predictions and Water Usage
Control on Steam Control on Steam Recommendations to
Cost

The recommendations Flow, no. of valves Flow, no. of valves ensure the right
are done by the ML/AI and locations and locations Moisture Output
models by learning the based on
patterns/correlations • Input Raw
between the input Material Quality
• Blend
variability and output
• Season
moisture

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The Process Digital Twin controls variability impact
Maintaining Moisture in leaves at the right level is Critical to Quality (CTQ) and Yield

Variability creeping in from sources and other upstream stations

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What are the steps to achieve the Goal?

DETECT PREDICT ACT

Middleware Machine Learning Artificial Intelligence

IT Systems
KEPWARE and SAP Regression class of Algorithms Reinforcement Learning for
to predict the impact of Control
Variability

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Bodhee can fit-in with any System Architecture
DETECT PREDICT ACT

• Pre-Conditioner MO
• Feed Rate Predict Control
• Raw Product Temp
Machine Learning & AI Models
K • Air Temperature
E • Input Moisture
PLCs • Current Valve Positions
P
on both inlet and exit
W • Current Water, Steam
A Pressures on inlet and
.
R exit Steam Pressure – Inlet, Exit
E Water Pressure – Inlet, Exit
.
. Valve Configuration Vector

By analyzing the shown input parameters, Bodhee® recommends the optimal

combination of valves and water, steam for reduced SD
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High-Level Approach on AI Implementation

Recommendations

Recommended values
for Water and Steam
Parameters

AI algorithms
Predictions Processes/ Machines
from Bodhee
Feedback, Self-Learning

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Architecture for Remote & Autonomous Operations

Primary Conditioner
Bodhee Web Interface
Operator Room

HMI

Read and Write Operations

PLC

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How is Bodhee working on the Line?

HMI

53
Bodhee successfully enabled remote operations

Bodhee Web Interface

Factory Floor HMI
which can control the process remotely

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Bodhee successfully reduced the Standard Deviation

Using Bodhee, the

recommendations were fed as
91%
input into the test data.

The recommended values

significantly reduced the
Standard Deviation of the
Output Moisture content thus
impacting the quality and yield.

The SD reduced from 1.76 to

0.15
Predicted output moisture content against the test data from the factory line

Note: The numbers shown above have been changed. Intent is to show the essence of
problem. But changed numbers are directionally consistent

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