Data Driven Quality Control Transformation in Manufacturing

How Azure-Powered Solutions Can Propel Data Analytics and Operational Efficiency to New Heights Data-Driven Quality Control Transformation in Manufacturing

CASE STUDY

Introduction Data difficulties for Quality Control and Optimization Ensuring quality control in manufacturing poses a critical, multifaceted challenge for operational efficiency and customer satisfaction. Predicting the quality of products is a significant hurdle, compounded by various factors that can affect the quality of a batch. Understanding and proactively adjusting these drivers is crucial for reducing waste, lowering the cost of goods sold (COGS), and improving lead times. These elements are key enablers of higher customer satisfaction and a more robust bottom line.

Challenge The Need for Data Maturity Our client, an industry leader in the advanced composite materials sector, faced operational challenges due to the complexity of their production process versus its limited data maturity. Navigating Data Silos for Customer Satisfaction The challenge was significant, as they lacked the necessary infrastructure to unify diverse datasets essential for comprehensive quality analysis. This absence of integrated data impeded their ability to proactively manage quality, with repercussions including excessive rework, production delays, waste management and customer satisfaction. Searching for a Cloud-Based Data Estate Our client sought to establish a state-of-the-art data estate in the Azure cloud to enable the advanced analytics required to examine product quality, its principal influencing factors, and many other critical business metrics.

The Quest for Cloud-Based Analytics Transformation Our client envisioned a future where cloud-

based analytics would clarify many facets of their operations. They aimed to harness this analytic firepower not just to answer questions about product quality but also to tackle an expansive range of other business-critical challenges. Fractal was uniquely qualified to address these challenges, leveraging its position as a leading analytics and data vendor with expertise in process manufacturing as well as the specialized competencies in driver analysis and data modernization.

Solution Enhancing Manufacturing Traceability with an Azure-Powered Integration

Fractal conducted an in-depth analysis to understand how to integrate the data from their disparate, geographically spread systems. The goal was to improve traceability and quality control in their manufacturing processes. Harnessing Microsoft’s Azure cloud technologies, we implemented a solution that provided immediate, actionable insights and set the foundation for advanced analytics, enabling long-term operational and strategic benefits.

OBJECTIVE

TECHNOLOGY STACK

REASON

Azure Data Lake, Azure Data Factory, Azure SQL Data Warehouse (Azure Synapse Analytics), Power BI, Azure Machine Learning

To establish a scalable, robust platform tailored for complex data manipulation and analytics

Leverage cloud-based Azure technologies for scalability and robustness

We implemented a comprehensive data management and analytics platform, leveraging Microsoft’s Azure cloud technologies. What we provided: Tools and Tech for Effective Data Management

To centralize all organizational data — sensor data, supply records, and other essential manufacturing information — creating a unified data repository To refine and prepare the centralized data, eliminating traceability gaps and making it suitable for downstream activities like data visualization and machine learning To facilitate data reporting and enable future analytics initiatives, making effective use of the integrated data for informed business decisions To deliver actionable insights within three months after deployment, providing quick time-to-value for the organization

Automate data movement to Azure Data Lake storage for a centralized data hub

Azure Data Lake, Azure Data Factory

Data transformation applying Azure Data Lake Analytics and U-SQL scripts for downstream applications

Azure Data Lake Analytics, U-SQL Scripts

Quick implementation time for quick time-to-value

Overall Azure Stack

Development of Power BI dashboards for enhanced reporting and future analytics

Power BI, Azure Machine Learning

Outcome

The immediate impact Our analytics solution gave engineers actionable insights into the key factors driving quality issues. As a result, timely adjustments were made in the production processes, leading to a noticeable reduction in quality defects. This immediate impact streamlined operational efficiency and conferred direct financial gains. Faster order fulfillment also resulted in reduced lead times for existing clients and enabled more competitive bids for new customers. Engineering Analytics Excellence Through Data Transformation The long-term benefits Over the long term, the value of our engagement persists through our client’s enhanced data maturity and the establishment of a modern data estate. This digital foundation enables our client to develop additional analytics solutions to tackle various manufacturing challenges. Moreover, by addressing key factors from earnings, the company is strategically poised for improved financial performance, giving it a competitive edge in a challenging market.

KEY BENEFITS

Reduced defect rate with improved quality control and reduced costs Increased operational efficiency with optimized product throughput

Streamlined order lead time, leading to improved customer satisfaction and responsiveness Supported long-term financial performance goals

Enable better decisions with Fractal Fractal is one of the most prominent providers of Artificial Intelligence to Fortune 500® companies. Fractal’s vision is to power every human decision in the enterprise, and bring AI, engineering, and design to help the world’s most admired companies. Fractal’s businesses include Crux Intelligence (AI driven business intelligence), Eugenie.ai (AI for sustainability), Asper.ai (AI for revenue growth management) and Senseforth.ai (conversational AI for sales and customer service). Fractal incubated Qure.ai, a leading player in healthcare AI for detecting Tuberculosis and Lung cancer. Fractal currently has 4000+ employees across 16 global locations, including the United States, UK, Ukraine, India, Singapore, and Australia. Fractal has been recognized as ‘Great Workplace’ and ‘India’s Best Workplaces for Women’ in the top 100 (large) category by The Great Place to Work® Institute; featured as a leader in Customer Analytics Service Providers Wave™ 2021, Computer Vision Consultancies Wave™ 2020 & Specialized Insights Service Providers Wave™ 2020 by Forrester Research Inc., a leader in Analytics & AI Services Specialists Peak Matrix 2022 by Everest Group and recognized as an ‘Honorable Vendor’ in 2022 Magic Quadrant™ for data & analytics by Gartner Inc. For more information, visit fractal.ai

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