Real-Time Predictive Analytics in Manufacturing

Real-Time Predictive Analytics in Manufacturing
Vivek A. Ganesan, Principal Architect Yue Cathy Chang, Sr. Director, Business Development
Impetus Technologies, Inc.
Big Data in Manufacturing
The Future of Manufacturing
INTELLIGENT DATA DRIVEN MANUFACTURING
2013 Impetus Technologies
Recorded webinar is available at http://lf1.me/hqb/

For more Info contact bigdata@impetus.com
More Data, Better Quality

Quality of Management Decisions
Intuition
Amount of Data Analyzed


Relevant
Data
Intuition


Accurate
Big Data
Relevant
Data
Intuition


Quick?
Accurate
Big Data
Relevant
Data
Intuition

We Have a Big Data Situation

When traditional information systems cannot
Store Process Analyze
Volume Velocity Variety
COST TIME


Volume
Sensors Machine data Internet of Things


Volume Velocity
Drinking from the fire hose! Consume or collapse!! Analyze at the speed of data?


Volume Velocity
Drinking from the fire hose! Consume or collapse!! Analyze at the speed of data?
Variety
Dealing with diagnostics
Binary data + log data

Ability to analyze variety of data formats

Where is the Value in Big Data?
Big Data and the Fourth V

The fourth V is Value
The Value of Big Data in manufacturing is in Analytics

Gartner defines four kinds of Analytics Descriptive Diagnostic Predictive Prescriptive

What? Who? How? Why? What if? Why not? Who else? What will happen when? What can I do about it?

Big Data Predictive Analytics

The formula is simple:
1. Collect data at every stage of the manufacturing process

2. Store data on a Big Data store
Economical, Accessible, Distributed, and Scalable
3. Process data
Manage the variety and complexity of the data
4. Analyze data
Apply mathematical models to make predictions

Predictive Analytics Context

Instruments
D A T A I N G E S T Model
Represent Learn Predict Iterate Improve
Predictions

Control
Fix Throttle Alert Adjust Optimize Abort
Batch Historical Iterative
Analytics
Real-Time
Immediate Instantaneous
Sensors
Feedback

Big Data, Big Value

In manufacturing, the greatest value is in :
Real-Time Predictive Analytics

Prescriptive Analytics is possible but depends on :
Good Predictions Fast Feedback Loop
Real-Time Predictive Analytics is the first step towards :
Intelligent Data-driven Manufacturing

Manufacturing Analytics Quadrant

REAL TIME
BATCH
Historical "What happened" Hindsight
DIAGNOSTIC
PREDICTIVE


REAL TIME
Near-term "What is happening" Insight
BATCH
DIAGNOSTIC
PREDICTIVE


REAL TIME
BATCH
Inferential "What may happen" Foresight
DIAGNOSTIC
PREDICTIVE


REAL TIME
Influential "Make it happen" Intelligent
BATCH
Inferential "What may happen" Foresight
DIAGNOSTIC
PREDICTIVE

Opportunities and Challenges

Business Opportunities
Preventive Maintenance
Real-time/near real-time actionable response
Technical Challenges
High Ingestion Rates
Sensor/tool data with subsecond ingestion requirements Millions of writes per second
Improve Productivity/Margins
Reduce wastes, improve efficiency Improve Yield
Complex Log Formats

Semi-structured data
Supply Chain
Optimize supply chain
Huge Amount of Data

TB/PB of data storage for deeper analytics

Let's Get Real!
Real-Time Predictive Architecture
Machine Data
NoSQL + Search

Real-Time Predictive Architecture
Machine Data
NoSQL + Search

Input Data: Raw Logs

Meta-data about the prospective product line is created at a factory site.
E.g., number of sensors emitting log files or readings.
Various log files are generated:

Containing Text. Containing specific Sensor readings, continuous as well as binary values. At each time-step, a specific pass/fail.

Input Data: Parsing

This data is parsed into a matrix representation Columns representing sensor logs Rows representing the time In our dataset: 590 attributes, approximately every minute
Missing Data from logs
Machine 1, sensor 1-120
Machine 12, sensor 1-92
Also has labels: {+1,-1} for failure/success from for each time-step 50,000 time-steps, i.e., 29.5 million values (parsed, not raw) in a month
Time
Failure : success :: 1 : 15
Interactive Visualization
Misalignment
Yield: 85% Failure < 1%
Time: 12:00
Machine 4, Tool 3, 4. Input from Machine 2.
Misalignment
Time: 12:01
Misalignment
Time: 12:02
Misalignment 30%
Alert: Machine 2, Tool 3, 12, 14 are not nominal
70%
Time: 12:03
Misalignment
Alert: Machine 2, Tool 3, 12, 14 are not nominal
90%
Time: 12:04
Alert: Machine 8 and machine 4 are failing. Cause: Machine 2 has voltage imbalance
Misalignment
Time: 12:05
90% Misalignment
80%
Time: 12:05
90% Misalignment
80%
Time: 12:05
Key Takeaways
Measure and Collect Everything Process, Diagnose, and Predict Get Real with Real-Time Generate Actionable Intelligence

Talk to us about Impetus Solutions and Services for Manufacturing Big Data
Assessment Objectives & Strategy Model BUSINESS PROCESS MANAGEMENT Analyze & Optimize People, Process, Technology Impact Solution Analysis Solution Modeling
Business Analytics and Data Science
Solution Architecture, POC and Production planning
Technology strategy, Use Case development & Validation
bigdata@impetus.com
Big Data Platform Implementation
bigdata.impetus.com
Operations and Visualization

Thank You
bigdata@impetus.com bigdata.impetus.com Recorded version available at http://lf1.me/hqb/

Real-Time Predictive Analytics in Manufacturing - Impetus Webinar

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Impetus Technologies, Inc.

Big Data in Manufacturing

The Future of Manufacturing

INTELLIGENT DATA DRIVEN MANUFACTURING

2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/

More Data, Better Quality

2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/

More Data, Better Quality

2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/

More Data, Better Quality

2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/

More Data, Better Quality

2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/

We Have a Big Data Situation

Store Process Analyze

Volume Velocity Variety

2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/

Big Data in Manufacturing

Sensors Machine data Internet of Things

2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/

Big Data in Manufacturing

Sensors Machine data Internet of Things

2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/

Big Data in Manufacturing

Sensors Machine data Internet of Things

Binary data + log data

2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/

Where is the Value in Big Data?

Big Data and the Fourth V

The Value of Big Data in manufacturing is in Analytics

2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/

Big Data Predictive Analytics

1. Collect data at every stage of the manufacturing process

2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/

Predictive Analytics Context

Batch Historical Iterative

2013 Impetus Technologies

Recorded webinar is available at http://lf1.me/hqb/

Big Data, Big Value