Using Predictive Analytics to Improve Product Quality and Performance
Case study in how Nexteer is deploying predictive analytics to improve critical manufacturing processes, optimize production and reduce costs.
TAKEAWAYS:
● Collecting and analyzing data from sensors, machine logs and other sources can identify patterns and anomalies, enabling engineers to take proactive measures that prevent downtime, optimize production and reduce costs
● Predictive analytics can enhance communication and collaboration throughout a manufacturing operation.
● Harnessing the power of data and advanced analytics is key to Industry 4.0-level digital transformation.
Automotive steering and driveline product manufacturer Nexteer wanted to improve its critical manufacturing processes as part of its Industry 4.0 journey. As one step on that journey, the manufacturer turned to predictive analytics technology to improve the functional performance for its motion control systems and reduce the reject rate for end-of-line function testing. This project was selected as a finalist for the 2023 Manufacturing Leadership Award in the Engineering and Production Technology category.
The objective of the project, which kicked off in January 2020, was to develop and implement predictive analytics tools such as Big Data and machine learning technology to identify features that have an influence on end-of-line function testing. This is a complicated task, since a typical assembly can include thousands of features, including component dimensions, assembly parameters, and process parameters. One key aspect of the project was to install IIOT-based real-time vibration and force monitoring on critical components of its manufacturing process, with the goal of moving problem solving from a reactive to a proactive mode.
The result: By generating insights from data, the company was able to detect anomalies sooner, which led to earlier detection of machine issues, as well as improved performance and reduced rejection rates.
Sue Pelletier is a contributing editor with the Manufacturing Leadership Journal.
Pravin Khurana, Ph.D. is Principal Manufacturing Engineer at Nexteer Automotive. He is responsible for leading IIOT and Advanced Data Analytics projects at Nexteer.
