Efficient Plant May 2020 - 20

feature | digital transformation

Digitize to
Deliver

Joe Gerstl, GE Digital

On-Demand
Production

Companies that provide data visibility are 30% faster at taking product
designs to production and 23% better at managing safety and risks.

TRADITIONALLY, SUCCESSFUL manufacturing
production has relied heavily on skilled personnel. Experienced employees installed equipment and implemented processes, relying on their expertise and intuition to
keep everything running at peak efficiency.
Times have changed and the baby boomer generation of engineers is retiring. To combat this loss of
knowledge, manufacturing companies are driving data
analytics as a top priority for their company. Using this
data, companies are able to "retrain" a new generation
of engineers by taking operational data and using tools
such as artificial intelligence (AI) and machine learning.
Combining these technologies with accumulated data
makes the new generation of workers more effective
than their predecessors by providing them with an
opportunity to react faster and be more productive.
Failure to implement robust digital capabilities puts
companies at a distinct competitive disadvantage.
It's no secret that data analytics have the power to
shift the competitive landscape. In fact, the number one
fear of companies unable to implement a data-driven
strategy is that competitors will gain market share at

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their expense. Today, it's the refined collection, analysis,
and application of data that optimizes efficiency and
productivity. Data-driven predictive asset maintenance
can save as much as 12% of scheduled repairs, reducing
overall maintenance costs by 30% and breakdowns by
as much as 70%.
Manufacturers suffer from excessive costs related to
materials, labor, packaging, and shipping. For the most
part, these added expenses are due to waste resulting
from rework, unscheduled asset downtime, maintenance, and late shipments. Predictive analytics have
the power to help reduce all of these costs. In fact, one
performance chemical company reports increasing
capacity by nearly 20% after adopting a predictiveanalytics model.

DEMAND AND DATA DELUGE
Production managers are tasked with keeping costs and
risk under control while producing what the market
wants, when it wants it, and at increasingly higher
quality-even when that means quickly changing lines
and entire facilities over to new products. The demand

MAY 2020

5/1/20 10:55 AM


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Efficient Plant May 2020

Table of Contents for the Digital Edition of Efficient Plant May 2020

Efficient Plant May 2020 - loc
Efficient Plant May 2020 - Cover1
Efficient Plant May 2020 - gatefold1
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Efficient Plant May 2020 - IFC
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