AI in glassmaking

Stop wasting money on failed

digitalisation projects
Yakup Bayram* highlights how many glass manufacturers are looking for data
driven solutions such as AI to support relatively less experienced workforces.
If the right process is followed a digitalization project can lead to more than
three times the ROI.

F
ailed investment in digital
transformation is a common story
for manufacturers across different
industries.
Because the glass industry is
experiencing a generational shift, many
companies are looking for a digital
transformation to support relatively
less experienced workforce with data-
driven solutions such as AI. However,
approximately 75% of AI projects never
make it to production. The good news is
that digitalisation can be successful if the
right process is followed, and it can lead to
more than three times the return on that
investment.
It’s no secret that the glass industry
is experiencing the collision of two
problems. An increase in the cost of
capital due to rising interest rates has � Mobile view of Polaris
made the optimisation of critical assets IoT sensor data.
such as furnaces a high priority; however,
the experienced managers who oversee
operation and optimisation of these assets When all of these first three steps are in superstructure using lidar.
are retiring away, leaving furnaces in the place, AI algorithms can be established for The data that is collected must be
hands of a younger, less-experienced predictability into what will happen next. uploaded to a digital platform so that it is
workforce. Digital transformation can be Finally, with the AI algorithms in place, visible to everyone and can be analysed.
a solution to preserve furnace knowledge autonomous processing is established as If everyone in the organisation has
and equip a young labour force to make the last fifth step. access to the same platform and the same
data-driven decisions. Why do so many of Data collection is an important set of data, there is a single, unbiased
these initiatives fail? step, because without the right data, source of truth.
Digitalisation is most successful everything else falls apart. Advanced PaneraTech’s platform, XSight, tracks
when the right steps are taken in the sensors provide deterministic data that risk and utilisation of each furnace in the
www.glass-international.com

right order to affect change across the
entire organisation. First, data must
be collected using advanced sensors.
Second, a platform is needed for visibility
of the data, which makes everything clear
and understandable for the operators.
Once this is in place, the third step,
transparency, becomes critical to building
a data-driven culture. With transparency,
the employees become more familiar
with seeing, understanding and drawing
conclusions from the data.
can be used as a basis for decision-making.
PaneraTech accomplishes this using
both portable SmartMelter sensors and
Polaris IoT sensors that are placed in
areas of high concern for continuous
monitoring of furnaces. Both sensors use
radar technology to map glass penetration
and measure residual refractory thickness.
We have recently added another
advanced method of data collection,
Digital Endoscopy, which measures
the thickness and movement of the
portfolio. Users can see an overview of
company assets and their colour-coded
health index, along with production data
and KPI’s. Furnace activities for each asset
can be reviewed, including observations,
maintenance performed, and inspections
or audits. The visibility provided by this
platform makes transparency possible.
When there is transparency across the
organisation, issues can be addressed
Continued>>
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Glass International October 2023
 AI in glassmaking
� Fig 1. Digital view of furnace bottom thickness.
early to preserve the life of the asset.
Operational mistakes can be identified
and corrected before more damage is
done. For example, one PaneraTech client
was surprised when a radar scan revealed
greater wear of the refractory on one side
of the furnace.
A PaneraTech Asset Manager reviewed
temperature data from each side and found
that cooling was poor on the side that
was wearing quickly. The Asset Manager
presented the findings with the entire
team through XSight software, bringing
transparency to the entire organisation.
Because of this transparency, action was
taken to improve cooling on the side with
accelerated wear.
At PaneraTech, the Asset Manager
plays an important role in helping
customers implement the fourth step
to digitalisation, building a data-driven
culture. This is a step where many
companies fail. You can bring in all of
the advanced tools, but if your team
www.glass-international.com
� Fig 3.
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Glass International October 2023
does not embrace data-driven decision
making, the project will fail. Resistance to
� Fig 2. Digital view of metal line thickness.
digitalisation is common, but it is often
from a lack of knowledge and training
on how to use data. Someone must be
the champion for building this culture
within the organisation. The Asset
Manager leads this effort and acts as a
mentor in the process.
PaneraTech Asset Managers have
extensive experience in glass furnace
management, and they are trained to
interpret production and sensor data.
Asset Managers work with customers to
create an action plan for operations and
maintenance, and they help to interpret
data and make recommendations.
Digitalisation succeeds when all these
steps are taken. The cost of not making the
transformation can be high, as seasoned
managers retire and a less-experienced
workforce attempts to take their place
with little training and no data. Turnover
and poor operational decisions can lead
to unnecessary damage.
However, the investment and effort
required to make digital transformation
succeed can be rewarded with an ROI of
more than 3X.
The best part for PaneraTech customers
is that we provide all the effort. Our team
does the work of building digital models,
uploading existing information, creating
the schedule, training your personnel,
and leading the effort of data-driven
decision-making.
Most of our customers find that they
break even within six to nine months
of asset life extension. We are excited to
lead our customers into the future with
Digital Furnace Monitoring. �
Paneratech, Chantilly, Virginia, USA
www.paneratech.com
yakup.bayram@paneratech.com