Manufacturing is one of the top 3 industries which account for the biggest share of the big data and analytics revenues worldwide. Manufacturing analytics have numerous use cases which enable businesses to predict machinery's future use, prevent failures, forecast maintenance requirements, and identify areas for enhancement.

We've compiled 14 success stories and case studies of deploying manufacturing analytics to help businesses identify areas for implementation.

What are the top use cases of manufacturing analytics?

Manufacturing data including machine and operator information can be processed and analyzed for:

  • Supply chain:
    • Demand forecasting
    • Inventory / asset management
    • Order management
    • Maintenance optimization
    • Risk management
  • Logistics:
    • Automation and robotics
    • Transportation allocation
  • Product development:
    • Product progress measurement
    • End user experience estimation
  • Sales:

To explore use cases in more detail, feel free to read our guide to the top 10 manufacturing analytics use cases.

What are some interesting case studies of manufacturing analytics?

Below is a list of case studies that we've compiled from different vendors and research resources:

Vendor Customer Country Industry Use Case Results
PTC SIG Switzerland Packaging & Containers Asset management & optimization - Discovered micro-outages that hadn't been tracked due to manual recording processes.
- Identified overconsumption of energy by certain machines.
- Increased speed of production line.
PTC Colfax USA Mechanical & Industrial Engineering - Predictive maintenance
- Asset management		 - Reduced service costs through remote monitoring and predictive maintenance of equipment.
- Detect patterns and anomalies in applications.
- Increased asset utilization
Rockwell Automation National Engineering Industries Limited (NEI) India Brownfield Factory - Predictive maintenance
- Risk management		 - Increased visibility into line, shop floor, plant and enterprise performance.
- Created a connected smart plant with integrated information from supply chain for factory scheduling, energy management system, resource allocation and material visibility.
- Avoided unplanned breakdown by taking proactive actions.
Rockwell Automation - USA Polymer & Coating Materials - Asset management
- Product development		 - 12% increase in production.
- 6% reduction in natural gas use/ton.
- 50% decrease in process variability.
SAS Kia Motors USA Automotives - Asset management
- Product development
- Predictive maintenance
- End user experience estimation		 - Forecasted failure rates and maintenance costs.
- Reduced production time.
- Categorized and extracted complaint types from customer surveys to uncover quality issues.
- Proactively alerted dealers to future maintenance issues to help them optimize repairs.
SAS Siemens Healthineers Germany Medical Technology - Predictive maintenance - Predict product failure probabilities.
- 36% less system downtime.
- Optimized service technician deployment, because they know in advance which parts are needed at a particular location.
Konux Deutsche Bahn Germany Railway Infrastructure - Asset management
- Predictive maintenance		 - Reduce 25% of maintenance costs.
- Reduce delay-causing failures.
Sight Machine - - Paper Manufacturing - Predictive maintenance
- Asset management		 - Identify hidden relationships between production parameters and quality issues.
- Create a digital twin of the production process
Sight Machine - - Automotives - Asset management
- Risk management		 - Built manufacturing data models.
- Implemented Root Cause Analysis (RCA) to identify the real source of the quality issue.
Sight Machine - - Industrial Manufacturing - Asset management - Identified $500K of potential saving costs in 3 weeks.
- Reduce scrap costs by 30%.
Augury - - Infant Formula Manufacturing - Preventive maintenance
- Inventory management
- Automation		 - Detected $350K worth of system errors.
- Identified opportunity for automating reliability practices.
- Early detection of fan malfunction which enabled the team to order parts without accruing expedited shipment costs.
FogHorn - China EV Charger Manufacturing - Predictive maintenance
- Asset management		 - Reduced false positive alerts generated by chargers.
- Anticipated maintenance needs
Mu Sigma - USA Food Manufacturing - Price optimization - Identified stores that had the potential to increase price of a product up to $0.25 from its closest competitor without impacting sales.
- Increase revenue by 2-3%.
Mu Sigma - - Energy - Inventory management - Optimized excess inventory and was projected to save $15M-$20M annually.

To explore manufacturing analytics vendor landscape, scroll down our comprehensive list of manufacturing analytics software and vendors.

And if you believe your business will benefit from a manufacturing analytics software, contact us to help you find the right solution for your business:

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