A 40% reduction in product wastage
Background
Challenge
- The line operated at over 600 devices per minute, leaving little room for manual intervention or visual checks
- Breakages could occur suddenly and severely, making on-the-spot diagnosis risky
- The speed and nature of the failures created hazardous conditions for operators attempting to investigate
- The fast-moving process made it difficult to pinpoint the exact source of the glass breakage
Solution
Recordings were triggered when events occurred, preventing the need to collect and analyse hours of data. PurpleSector also developed AI-powered vision algorithms – programmed to filter out normal machine vibrations – to analyse how individual products moved through the production line. These algorithms identified areas of unexpected movement and displacement.
Results
The bad actors within the system were rapidly diagnosed and digital twinning simulations were used to optimise the line. The project achieved close to a 50% reduction in minutes lost to glass breakage and a 40% reduction in glass breakage.
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We deploy F1™ - derived tools, technologies and techniques to help organisations operate like an F1™ team. Our goal is to build the in-house capability for clients to solve challenges, uncover opportunities and deliver performance gains at race-pace.
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