People, Productivity & Safety

Safety

Safety automation makes it easy to update SOPs and create emergency plans without disrupting daily 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 deflecting time and effort from value-adding activities. Symphony Industrial AI digitizes 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.

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 building blocks allow customers 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.