Operational Visibility

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

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Problem

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Solution

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Results

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Traceability

Gain accuracy and traceability by generating a digital thread by recording before, during, and after each physical and digital transaction. 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.

Sustainability

Minimize negative environmental impact while conserving energy and natural resources with sustainable processes. 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.

Materials Receiving

Automating the receiving process decreased unload times, therefore reducing labor costs. Receiving automation also eliminates human error and allows for precise and accurate assessment of inventory and incoming quality. Whether you run an oil & gas refinery or a multinational food processing operation, improving the efficiency of your operations begins with the receiving process.

Efficiently receive, process, and validate incoming materials

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Problem

The customer had inconsistent processes for truck check-in across a geographically dispersed operation. At certain facilities, trucks would wait for hours to unload raw material. At others, experienced operators were more efficient and kept trucks moving.


Solution

Symphony IndustrialAI automated the process to drive consistency across all facilities. Operators would scan the materials to confirm the contents of the truck matched the bill of lading and passed initially quality screening. Once approved, the operator could issue payment to the independent truck drivers and get them on their way.


Results

The customer was efficiently and consistently able to increase on-time delivery, improve quality and reduce inventory.


Capacity and Throughput

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

  • 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.

Electronic Batch Records

With electronic 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.

Supply Chain Integration

Connect people, suppliers, and customers to a single source of truth. 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.