Centralized Quality Tracking System - Vertex Computer Systems

CASE STUDY

Centralized Quality Tracking System Using Complex Event Analytics (CEA)

Abstract As a leading North American Steel producer, this manufacturer recognizes that identifying quality gaps, reducing waste, and improving manufacturing operations – leveraging new technology, capabilities, frameworks, and a data-driven approach – are instrumental for continued quality improvement, distinction, and sustaining competitiveness in the market.

BOSTON | CHICAGO | CINCINNATI |

CLEVELAND

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2245 Enterprise Parkway East, Twinsburg, OH 44087, Tel: (330) 963-0044, Fax: (330) 963-3566 Email: [email protected] www.vertexcs.com

| INDIA

Summary

and being returned. This issue occurs because

The current steel manufacturing process includes over a dozen different mills, each of

the defined “tolerances” for each line are being met, but there is a larger QA gap across lines

which are cumulating very large amounts of

and mills which were not being identified and

sensor and quality data (tens of thousands of

addressed.

metrics captured and stored on second and sub-second intervals) while producing each

The impact of these Non-Prime coils reaching

coil of steel. While there are machine sensors and isolated analytics tools in place today which help to manage quality and tolerances at specific points within the process, there is no system in place which monitors product quality

the customer can be substantial for both the manufacturer (production, re-mill, scrap cost) as well as the customer (delays in sourcing, production, lost sales). Vertex was engaged to build upon the existing

throughout the lines, across the mills, providing a complete view (and tracking) of manufac-

CEP information to develop a Complex Event Analytics (CEA) solution which proactively iden-

tured materials (e.g. finished goods) from start to finish. This lack of visibility across the entire

tifies and addresses these challenges, and brings a scientific approach to managing qual-

manufacturing process results in gaps with quality, association, tolerances, and root cause

ity factors and improvements.

analysis which were not being addressed.

Solution Highlights

To bridge this gap and help accelerate QA from traditional manual Complex Event Processing system to context-aware, data-driven processing, Vertex worked closely with this Steel manufacturer to develop a purpose built Complex Event Analytics (CEA) solution which threads together sensor-based, timestamped datasets from 14 mills (and various systems) into a product-centric view for detailed analysis. Advanced Analytic applications provide identification, root-causing, and error association, progressing towards data-driven rules definition for Complex Event Processing (CEP) systems.

Vertex is creating a combined custom data management and Advanced Analytics solution which is enabling a shift in analysis and management of quality metrics and processes for this manufacturer – allowing them to move from unthreaded time and sensor location-based analysis, to batch level, start to finish, product-centric analysis and quality monitoring.

Business Challenge As for many manufacturers, the visibility of quality and how it is impacted by a multitude of factors across mills and across a stream of activities is limited. On occasion, Non-Prime steel coils which “look” good, pass all quality tests and do meet current QA standards for each step in the process, but does not meet Total Quality standards is reaching customers

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The solution is constructed into two

Business Impact

phases. Phase I provided the architecture framework for end-to-end Data Consolida-

Trace Across Mills

Problem Iden!fica!on

tion, and compiles and threads information Root Cause Analysis

together in the CEA data lake, which provides the basis for advanced analytics and

Replay

statistical modeling. Additionally, off-line analytics, Descriptive Modeling, and an

Compare & Contrast

Evaluate Associa!ons

iterative process for cause-and-effect analysis was leveraged to identify root causes of quality issues identified.

Leveraging the wealth of information gathered

Phase II will provide automation of effec-

during the manufacturing process, merging into a Data Harmonization Layer where end-to-end

tive methods in connection with the transactional Complex Event Processing (CEP)

sensor readings gain context through association with individual item numbers (e.g. coils),

systems, enabling a fine-tuned, optimized QA process which exceeds measure-

and connecting with Advanced Analytics through an easy-to-use application layer, this Steel Manufacturer is now able to identify and distinguish defective coils, perform Root Cause Analysis, access inter-connected data points across mills, review historical trends, fine-tune

ments and metrics that exists today and enables a greater return on investment.

About Us Vertex is a CMMi Level-3 IT consulting organization that engages with its customers at a strategic level and provides ‘thought leadership’. Vertex’s team of Solution Scientists craft innovative solutions, with a holistic view, that make businesses smarter. Vertex acts as an advisory partner, aligning its offerings with the business goals and objectives of its customers.

quality metrics, measures, and tolerances, and more. System expansion will incorporate additional statistical approaches and Real Time Predictive Analytics for pro-active intervention, ultimately leading to the institution of a comprehensive QA approach across the complete production process, and further helping to minimize total quality issues resulting in improved ROI and customer satisfaction.

For more information, reach us at [email protected] 2245 Enterprise Parkway East, Twinsburg, OH 44087, Tel: (330) 963-0044, Fax: (330) 963-3566 Email: [email protected] www.vertexcs.com

BOSTON | CHICAGO | CINCINNATI |

CLEVELAND

| COLUMBUS

| INDIA