As an example, a leading food manufacturer was able to drive down customer complaints by more than 33% through analytics. The manufacturer had struggled with weight control on a cube-shaped product. Make the cubes too heavy, and the manufacturer was giving away product or producing watery product if the excess weight was due to too much water. When the cubes were too light, the company was in regulatory jeopardy as well as having trouble compacting the product into a stable cube shape.
The team used Proficy CSense to get a complete, correlated-by-lot and period picture of: ingredient specs, process variables as run, and lab data – using the software to look for controllable factors that correlated to excess giveaway and then comparing periods with better weight control to the factors that were true then. Now, when the team sees how a raw material variance was successfully corrected for or a process disturbance was overcome, that understanding is embedded into a new material spec, recipe or SOP. The smart analysis with Proficy CSense yielded other benefits as well.
Another example involves applying a smart predict project at a pulp and paper manufacturer to predict Critical to Quality (CTQ) KPIs to improve productivity and eliminate wastewater regulatory issues. As a final example, a partner in mining delivered an Advanced Process Control solution that increases throughput by 10% using smart optimization technology.