Plant Operations

Directed Work

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

OCAP

In statistical process control, Out-of-Control-Action Plan (OCAP) are the steps that must take place after 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.

Materials Verification

Material Verification assists with changeover setup, ensuring the right components are loaded into the right place, expediting set up time, ensuring part accuracy, and minimizing 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.

Quality

Quality of design and conformance to specifications are crucial to producing 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.

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. Symphony IndustrialAI automates these processes, including:

  • 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.