The manufacturing industry is increasingly relying on tools for data analysis. Current systems are mostly used to explain the current situation or provide an outlook on future developments. This helps companies and speeds up processes. Even better would be a system that gives employees detailed recommendations for action - with transparency about the effects of the individual alternatives. The fields of application for such systems in production are many and varied. For example, companies can use them to optimize supply chains and the sequence of production orders. The systems use up-to-date data and leave the final decision to the responsible employee.

This prescriptive analytics approach is made possible by AI and machine learning (ML) for linking and evaluating the available data from production. The basis for this is an intelligent data platform with an integrated workflow engine that aggregates, harmonizes, normalizes and evaluates all relevant data from the systems, such as the MES, in real time.

Precise overview of the entire production process

Prescriptive analytics enables companies to make better decisions faster. One obvious area of application is the flexible optimization of the sequence of production orders. This is particularly important in the current crisis situation, which demands a great deal of flexibility from companies. As a first step, the technology helps to optimize production planning. This guarantees high machine utilization. The system also makes suggestions if employees need to reschedule later, for example due to a shortage of raw materials. There is always a connection between the solution and the systems involved - the MES or the Enterprise Resource Planning (ERP) system. From material procurement to shift planning, companies can therefore address all production processes in their analyses and control them accordingly.

Such a solution is also a basis for reducing energy costs and achieving sustainability goals. This is because it can automatically schedule energy-intensive processes for times when electricity is particularly cheap or available from a sustainable source.

Prescriptive analytics also allows employees to anticipate the imminent failure of a machine and react at an early stage. This allows them to avoid the sudden failure of a machine and reschedule production so that an optimal maintenance window is available. With regard to prescriptive analytics, it is also always about the availability, linking and quality of your own data. Companies need to use up-to-date and accurate data to ensure that their forecasts are correct. However, as a study by IDC shows, there is often a lack of comprehensive networking between IT and OT.

Data platforms

In addition to core elements such as the MES or ERP system, companies therefore need another component that ensures modern data management and interoperability. Building on this, the new technology around prescriptive analytics can perform analyses, optimize processes and control them.

This requirement profile is met by modern data platforms - such as IRIS from InterSystems - which link, harmonize and normalize data of all formats from various sources. In doing so, they break down data silos and close the gap between IT and OT. In order to achieve the outlined results, companies must take certain measures in advance. Three points play an important role here:

• Initially, employees are faced with the task of defining a clear business case and specifying their goals. This enables companies to economically justify the introduction of prescriptive analytics and prove the subsequent success of the project before the go-ahead is given.
• It is important to standardize your own master data.
• Companies must ensure organizational development. A lack of acceptance among those affected quickly leads to project failure.

A successful project at the right time can become an important lighthouse project. Based on the experience gained with prescriptive analytics, companies can later implement further process control projects.

Author: Werner Reuß, Manufacturing Solutions Executive