Solutions

The Symphony Industrial AI Platform solves a wide range of challenges for manufacturers from semiconductors to soy beans.

Safety

Safety automation makes it easy for companies to update SOPs and create a plan of action in the case of an emergency. Plus, it can all be done in a quick and efficient way that does not disrupt normal operations. Symphony Industrial AI’s Safety features include:

  • Automate changeover and SOP work instructions
  • Machine lockout, auto-line stop
  • Real-time monitoring
  • Operator certification/verification
  • New hire training/onboarding through directed work

Reducing safety incidents to near zero

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Problem

Our customer faced catastrophic failure if process was not followed and chemicals added to batch in the wrong sequence. This caused downtime, decreased productivity, and safety process and equipment were often circumvented.

Solution

Symphony Industrial AI automated the customer’s SOP and processes. The new system presents critical information to operators when needed to guide the work and ensure compliance and deployed globally to 40 plants.

Results

This reduced the compliance risk and brought the number of safety incidents to near zero ultimately increasing productivity and yield.

Paperless Factory

Manual paper-based systems hinder manufacturing excellence by incurring safety, productivity and quality costs on the shop floor and are deflecting workers’ time and effort from value-adding activities. Symphony Industrial AI helps digitize paper workflows with:

  • Automated data collection, SOP’s and paper traveler ensuring accuracy and efficiency
  • Spreadsheet automation
  • Automatic capture of data and trends via Historian

30% improvement in productivity

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Problem

Paper-based SOPs and work instructions pose a challenge for both the managers authoring and maintaining them and the workers implementing them. For workers, it often means sifting through 100-page long manuals to find relevant information while management faces the challenge of updating and distributing paper documentation. Often the SOPs simply aren’t updated, or worse, best practices aren’t documented and shared.

Solution

Rather than simply converting paper to PDFs, Symphony Industrial AI helps our clients consider more than just the method of delivery, we help envision the type of data, the interactivity of that data, its revision control and automating processes where appropriate.

Results

One customer saw 30% improvement in productivity as operators were able to bring up the correct revision assembly instructions, dynamic video assistance, CAD images, BOM information combined with sensor data to guide the operator through corrections.

Traceability

Generate a digital thread by recording before, during, and after each physical and digital transactions for greater accuracy and traceability. Symphony Industrial AI’s Traceability features include:

  • Real-time monitoring and reporting
  • Visibility and traceability of processes and actions for compliance, safety and root cause analysis
  • Provide a digital thread, Symphony Industrial AI is your process system of record

Symphony Industrial AI’s Historian covers end-to-end traceability both inside the plant and through the supply chain

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Problem

Challenges with traceability impact many different industries, including food and agriculture, chemical and high-tech manufacturing. traceability is used to comply with regulations, minimize risk and track details.

Solution

Symphony Industrial AI helps our customers trace work items throughout the manufacturing lifecycle. Our customers can use the rich, contextualized data to collaborate with stakeholders and customers throughout the supply chain for real-time monitoring of attributes such as location, status and quality.

Results

Traceability can prevent recall problems, minimizing damages, as well as ensuring quality management. Symphony Industrial AI’s historian covers end-to-end traceability both inside the plant and through the supply chain.

OEE

OEE (Overall Equipment Effectiveness) is a standard for measuring an asset’s level of productivity. OEE is a great metric for accurately identifying losses, and improving the productivity of manufacturing equipment (i.e., eliminating waste). Symphony Industrial AI can show:

  • Asset performance and availability
  • Quality monitoring

Customer realized they were only achieving 50% utilization rather than the 90% they had accepted as peak performance

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Problem

When assessing OEE, most customers focus on absolute measures of uptime—equipment is either available or unavailable—and ignore nuanced findings, such as minor stoppages that don’t result in a complete shutdown. These binary reports don’t provide engineers with a detailed fact base for factors contributing to production issues, making it difficult to craft improvement strategies.

Solution

Symphony Industrial AI connects the systems, tools, and historian to automatically collect, store, monitor and track the end-to-end manufacturing process. The system monitors asset performance and availability and the nuanced metrics that drive OEE.

Results

Symphony Industrial AI Historian provide the insights needed to help reduce downtime, displaying categorized events and highlighting production bottlenecks. One customer discovered that upon closer examination, they were only achieving 50% utilization, rather than the 90% they had accepted as peak performance.

Quality

Quality of design and conformance to specifications provide the fundamental basis for managing operations to produce high quality products. Symphony Industrial AI supports Quality programs through:

  • Real-time Anomalies/drift monitoring, including SPC, oscillation and upper/lower limit processing
  • Automate OCAPs (out of control action plans)
  • Root cause assessment
  • Quality assurance
  • Digital thread
  • Advanced planning
  • Digital Lean/ ongoing improvements

Lowering the cost of quality

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Problem

Our clients are continually refining processes to extract cost and reduce margins for error. With higher targets and stricter quality control, manufacturers require a platform that enables continuous improvement and sends alerts when processes exceed parameters.

Solution

Symphony Industrial AI connects the systems, tools, and historian to automatically collect, store, monitor and track process data throughout the supply chain. The system monitors operations for conformance and rapid self-correction and the nuanced metrics that drive quality.

Results

Symphony Industrial AI increases efficiency and enhances quality control enabling lowering the cost of quality by building a repository of quality data and measurements to identify top issues and trends, make improvements, measure and sustain quality initiatives.

OCAP

In statistical process control, Out-of-Control-Action Plan (OCAP) describes the sequence of activities that must take place following the occurrence of an activating event generally pertaining to quality control. Symphony Industrial AI supports OCAP via:

  • Process failure monitoring and automated response
  • Changeover
  • Digital action plans
  • Change acceleration
  • Root cause analysis

Expanding asset life by years, avoiding new capital outlays

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Problem

Rapid change in the semiconductor industry drove increased volume & complexity. Fab manufacturing steps increased from 250 to 2,000, lead-times from 30 to 90 days, and untenable scrap levels. Increased process steps were driving the need for large increases in labor, plant resources and equipment.
Our customer had limited visibility to timely production and quality information due to a proliferation of systems and applications that were not integrated and paper-based processes. And, leadership had aggressive goals to make quantum leaps in capability, productivity, yield, flexibility and lead-times, and continuous improvement

Solution

Workflow automated the end-to-end fab process, connected the enterprise, optimized operations, enabled analytics and innovation, and extended the digital capability of plant and equipment. ​

Results

Significant improvement in capacity, quality, lead-time & on-time delivery with lower headcount along with extended life of equipment, reducing capital requirements. ​One customer extended the life of equipment by years which paid for the system in a matter of months.

Sustainability

Sustainability focuses on the creation of manufactured products through economically-sound processes that minimize negative environmental impacts while conserving energy and natural resources. Sustainable manufacturing also enhances employee, community, and product safety. Symphony Industrial AI helps our clients design in sustainability with:

  • Energy and water monitoring and alerting
  • Clean in-place functionality
  • Energy performance
  • Integrated energy, production, and materials usage reporting

Demonstrate impact of sustainability initiatives

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Problem

To support and grow sustainability initiatives, Symphony Industrial AI customers need the data to show reduction in costs, as well as the reduction in risk: regulatory as well as reputation and brand.

Solution

Symphony Industrial AI integrates reporting from disparate systems such as energy and water consumption, materials usage reporting, and safety procedures.

Results

Armed with this data, Symphony Industrial AI customers not only reduce costs and risks but have increased sales as a result of sustainability projects. Our customers can demonstrate the impact of sustainability on manufacturing, transportation, use through end-of life, and have enhanced their brands (and sales) as a result.

Directed Work

Automate workflows and create a digital paper trail for reference and continuous improvement.

Symphony Industrial AI incorporates three critical components not found in common workflow tools:

  • Business and manufacturing systems data integration
  • Manufacturing process execution
  • Manufacturing intelligence

These are the building blocks to realize the gains of a digital factory.

Achieve payback in months with gains in productivity and safety

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Problem

This customer processes chemicals in a highly regulated industry. Their manual process made the tracking and tracing of each step in the chemical manufacturing process difficult and inconsistent. This made regulatory audits time consuming and risked significant downtime.

Solution

Symphony Industrial AI was selected to create and implement a digitized SOP solution in just eight weeks, followed in short order by a rollout to six sister plants.

Results

The Symphony Industrial AI platform was able to quickly enhance the safety and productivity across the entire operation, ultimately achieving payback in months.

Smart Changeover

Changeover represents the time and process of converting a line or machine from processing one product to another. Depending on the facility and industry, changeover times can range from minutes to several weeks.

  • Automated changeover
  • Start and stop monitoring
  • Machine lockout
  • Downtime tracking
  • Enable SMED through step-by-step instruction

Dramatically reduce changeover time

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Problem

Wasted time is wasted money. Valuable time and resources spent converting a line or machine is time and resources not spent creating producing value for the organization.

Solution

The Symphony Industrial AI platform automates changeover and monitors downtime across systems and plants. Symphony Industrial AI can generate and record the data necessary for SMED and Lean manufacturing initiatives.

Results

By reducing the costs of changeover, Symphony Industrial AI has saved our clients millions and resulted in rapid ROI.

Predictive Maintenance

Track equipment performance trends over time to predict downtime and uncover rich, contextual insights and avoid outages. Symphony Industrial AI helps through:

  • Fault detection alerting
  • Asset performance monitoring
  • Monitor events – process drift
  • Capture – respond to events
  • Maintenance systems and mechanics notification

Reduce the costs of unscheduled downtime and extend the life of key assets

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Problem

New and retrofitted machines have sensors which, if connected, aren’t centralized for comprehensive performance monitoring. By tracking these data points over time, managers can predict downtime and avoid outages.

Solution

By connecting machines and plants to a central dashboard, customers can centrally monitor sensor data such as vibration and temperature over time and maintain equipment before a line goes down.

Results

The benefits of Predictive Maintenance are wide ranging; customers not only avoid the costs of unscheduled downtime, but the costs to maintain and repair equipment goes down and the life of key assets gets extended.

Capacity and Throughput

Increase visibility into equipment capacity and throughput and enable employees to address problems before they arise with real-time asset monitoring, predictive analytics, and smarter work instructions:

  • Monitor speeds, feeds, downtime, yields
  • Self-correction
  • OEE/Asset efficiency
  • Automate OCAPs
  • Downtime alerts

Double digit increases in capacity and throughput

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Problem

Plant managers lacked the visibility into which equipment was slowing the line and causing lower productivity. The ERP and plant control systems weren’t integrated and key data wasn’t getting to the right people.

Solution

With the Symphony Industrial AI platform, our customers can connect to various systems and bring new levels of visibility revealing data and insights that were previously hidden.

Results

Double digit increases in capacity and throughput can be realized immediately through increased visibility and control. Further gains come from reducing waste and optimizing key plant and equipment. Most profoundly, Symphony Industrial AI helps empower the ingenuity of your greatest asset, your people.

Recipe Management

With a digital recipe management system's batch records, you can ensure master batch records are accurate and batches are completed correctly and efficiently.

  • Integrated process and equipment orchestration
  • Materials verification
  • Recipe or BOM management
  • Regulatory and compliance tracking and control

Increase quality and improve regulatory compliance and reporting

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Problem

30% of our customer’s master batch records required a recipe or formula variation but legacy systems wouldn’t allow for easy updates.

Solution

Symphony Industrial AI allows the customer to manage changes directly from the master batch record. This makes it possible to improve data integrity, compliance, and control.

Results

With easier integration of recipe changes and various inputs, the client was able to increase quality and improve regulatory compliance and reporting.

Materials Verification

Material Verification assists with changeover setup, ensuring the right components are loaded into the right place; expedite set up time, ensure part accuracy, and minimize scrap by removing the opportunity for human error. With Symphony Industrial AI you can:

  • Automate ingredient and parts verification
  • Integrate order, recipe, materials and loading orchestration
  • Perform compliance monitoring

Consistently produce top quality products

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Problem

The customer had a wide variety of colors in their products. It was critical to get exactly the right amount of color and the right mix of colors to get the highest quality finish in a consistent and predictable manner.

Solution

Symphony Industrial AI automated the process to select the recipe, operators would then scan the materials to confirm the right color was used and were told how much of each pigment to add to the mix, this ensures that the exact amount is added and information on pigment recorded and automatically stored with the batch so the customer had a detailed record of the ingredients used for each product created.

Results

The customer was efficiently and consistently able to provide top quality products to their customers.

Advanced Analytics (AI/ML)

With Symphony Industrial AI, your business intelligence and enterprise planning workflows are augmented with rich integrated and contextualized asset, process and event data. Symphony Industrial AI supports AI/ML initiatives with:

  • Real-time end-to-end production execution data
  • Workflow response

Avoid digital exhaust – treat data like the asset it is

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Problem

Our client’s key data was dispersed and hidden in legacy systems that weren’t connected to the main business intelligence system.

Solution

By connecting legacy systems and transforming the data, our client was able to easily import the data in RStudio that radically improved their AI data models.

Results

AI/ML is a megatrend that is transforming business across industries. A key enabler for our customers is not having to send data scientists to explore each plant system. Rather, plant managers and operators can expose data and workflows that were previously inaccessible unlocking the insights that deliver on the promise of the smart factory.

Supply Chain Integration

Connect your people, suppliers, and customers to a single source of truth. Companies can use supply chain analytics to monitor warehouse, partner responses and customer demand for better-informed decisions via features such as:

  • Central data broker
  • Full transaction audit
  • Supply and customer integration

With greater visibility identify nodes in the supply chain that can be optimized

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Problem

Supply chains generate massive amounts of data. The challenge comes when trying to make sense of it all — uncovering patterns and generating insights, then empowering engineers and operators to take action.

Solution

Symphony Industrial AI supply chain analytics helps to make sense of all this data. Customers can project and mitigate disruptions and risks by integrating disparate sources into Symphony Industrial AI’s central data broker.

Results

With greater visibility to supply chain data, customers can better predict future demand helping to decide what products can be minimized when they become less profitable or understanding which nodes in the supply chain are costing time and resources. One customer saved millions by just shaving a minute off truck receiving process.