Key Benefits
About the client
The client is one of the agencies of the US government. The client specializes and in charge of the manufacturing of massive energy production. The client was using in-house manufacturing execution systems and products from competitors.
Problem statement
While being a government agency and a leading name in massive energy production, its operations and maintenance were heavily relying on manual work. A major pain point was older machinery, lack of efficient digital communication, lack of embedded sensors, and ability to move from reactive to predictive operations. The client had no way to predict failures nor RUL (Remaining Useful Life) of the machines, hence, no accurate way to track the degrading efficiency and productivity. The client was in urgent need of an immediate yet effective solution that can scale across types of products.
The solution
The client learned about the GEM Precare Cloud solution, which provides real-time ML and AI-based insights into the equipment's overall efficiency so that corrective steps can be made to improve overall equipment effectiveness and service quality. The solution incorporates connection and big data analytics into Industry 4.0 digital twins of equipment, such as turbines, generators, engines, and infrastructure in general, to improve overall equipment efficiency via real-time and predictive analytics.
Deployment of solution
The solution deployment started in 2019 with the following products:
GEM started the deployment of the solution using its machine onboarding and analytics frameworks. The company started the deployment with 1 virtual factory floor and 2 machines. GEM tested and trained the AI and ML models and deployed the models followed by documenting them.
Key Results
With the deployment of the GEM Cloud, Edge, and AI/ML package solution, the client observed tangible and immediate benefits. The client was provided with end-to-end generic workflows for RUL of the machinery by collecting data and preprocessing it through GEM’s efficient AI/ML algorithms. Additionally, the client was also provided with approaches for accurately predicting the RUL for the machinery they were running.
Additionally, the following benefits were also observed:
Conclusion
Today, the GEM Precare
SaaS Predictive Analytics Industrial IOT Platform Is stronger than ever. GEM real-time & Predictive analytics are top of the lines in the Semiconductor, Electronic Manufacturing, and Automotive. GEM enables any customer user, from executive to machine operator, to get critical operational analytics insight, allowing them to take predictive actions. GEM Agents are able to take full advantage of the hardware they run on for complex event processing at the edge rather than in the cloud. It allows real-time remote monitoring and visualization via the cloud of critical parameters and signals with notifications for alarms and other events. This significantly helps manufacturing organizations reduce latency for time-critical monitoring and control applications.