Data-driven quality control transformation in manufacturing

Ensuring quality control in manufacturing poses a critical, multifaceted challenge for operational efficiency and customer satisfaction. Predicting the quality of products is a significant hurdle, compounded by various factors that can affect the quality of a batch.

Understanding and proactively adjusting these drivers is crucial for reducing waste, lowering the cost of goods sold (COGS), and improving lead times. These elements are key enablers of higher customer satisfaction and a more robust bottom line.

Our client, an industry leader in the advanced composite materials sector, faced operational challenges due to the complexity of their production process versus its limited data maturity.

Navigating data silos for customer satisfaction
The challenge was significant, as they lacked the necessary infrastructure to unify diverse datasets essential for comprehensive quality analysis. This absence of integrated data impeded their ability to proactively manage quality, with repercussions including excessive rework, production delays, waste management and customer satisfaction.

Searching for a cloud-based data estate
Our client sought to establish a state-of-the-art data estate in the Azure cloud to enable the advanced analytics required to examine product quality, its principal influencing factors, and many other critical business metrics.

The quest for cloud-based analytics transformation
Our client envisioned a future where cloud based analytics would clarify many facets of their operations. They aimed to harness this analytic firepower not just to answer questions about product quality but also to tackle an expansive range of other business-critical challenges.
Fractal was uniquely qualified to address these challenges, leveraging its position as a leading analytics and data vendor with expertise in process manufacturing as well as the specialized competencies in driver analysis and data modernization.

Fractal conducted an in-depth analysis to understand how to integrate the data from their disparate, geographically spread systems. The goal was to improve traceability and quality control in their manufacturing processes.
Harnessing Microsoft’s Azure cloud technologies, we implemented a solution that provided immediate, actionable insights and set the foundation for advanced analytics, enabling long-term operational and strategic benefits.

What we provided:
Tools and tech for effective data management
We implemented a comprehensive data management and analytics platform, leveraging Microsoft’s Azure cloud technologies.

The immediate impact
Our analytics solution gave engineers actionable insights into the key factors driving quality issues. As a result, timely adjustments were made in the production processes, leading to a noticeable reduction in quality defects. This immediate impact streamlined operational efficiency and conferred direct financial gains. Faster order fulfillment also resulted in reduced lead times for existing clients and enabled more competitive bids for new customers.

The long-term benefits
Over the long term, the value of our engagement persists through our client’s enhanced data maturity and the establishment of a modern data estate. This digital foundation enables our client to develop additional analytics solutions to tackle various manufacturing challenges. Moreover, by addressing key factors from earnings, the company is strategically poised for improved financial performance, giving it a competitive edge in a challenging market.

KEY BENEFITS
• Reduced defect rate with improved quality control and reduced costs
• Increased operational efficiency with optimized product throughput
• Streamlined order lead time, leading to improved customer satisfaction and responsiveness
• Supported long-term financial performance goals.