Solution Brief
Improve manufacturing quality
Quickly improve product quality, yield and revenue with trustworthy data and AI.
The issue
According to the American Society for Quality, many manufacturing companies have quality-related costs as high as 15%-20% of sales revenue, with some as high as 40% of total operations. A lack of visibility across the value chain hampers a manufacturer’s ability to react to changes in product quality and operational performance. Data comes from many systems, including MES, CMMS, MRP, MOM, EAM, SCM and S&OP.
Making fact-based business decisions is difficult without connecting and analyzing data to gain real insights, leaving manufacturers to rely on employee intuition and guesswork. This further increases the costs of poor quality due to wrong decisions based on incomplete information. If left unaddressed, poor quality and low yield eventually lead to dissatisfied customers and reduced competitiveness in the marketplace.
The challenge
When it comes to improving product quality and throughput, manufacturers face numerous challenges, including:
Quality control
Poor quality makes meeting production goals challenging and eats away at time, resources, yield and revenue.
Production issues
Failures and lack of insights into the production process can create challenges in meeting production goals.
Rising costs and waste
Inefficiencies create unnecessary expenses, material waste and energy usage, also affecting sustainability efforts.
Disparate data sources
Not being able to use data for insights makes it difficult to resolve root-cause issues quickly or be innovative enough to stay competitive.
Take advantage of AI to:
(Meet or exceed production goals; Predict and prevent future issues, waste and lost sales; Quickly discover root causes and implement corrective actions; Automate, monitor and optimize processes in real time; Enhance customer satisfaction; Improve sustainability so you stay competitive)
Our approach
Lack of critical information leaves manufacturers unable to solve underlying quality problems. Without a clear understanding of quality’s effects on cost and demand, organizations can be left with unexpected expenses, reduced yields and low customer satisfaction. SAS manufacturing quality software helps solve quality issues. We enable you to integrate and rationalize data from disparate systems and apply AI and machine learning, deep learning and neural networks to uncover the insights needed to make informed decisions while minimizing risk quickly.
We approach the problem by providing manufacturing quality software and services that help you:
Improve product quality while reducing costs
Increase your competitive advantage with higher quality and lower cost per unit.
Optimize production yield
Improve operations with deeper, trustworthy insights that help you meet or exceed production goals.
Improve processes, sustainability and profitability
Achieve process optimization that supports safety and sustainability and generates value across the business.
Reduce complexity and accelerate innovation
Gain a one-stop shop that grows with you. SAS ensures the data users need is right on their desktops for fast, actionable insights.
Customer Case Study
This global manufacturer of home appliances was competing with many new market entrants who were eroding revenue and margin by offering similar equipment at a lower price. To effectively compete, the company wanted to focus on further differentiating its quality. Using SAS predictive analytics and reporting, the manufacturer improves quality beyond its already high standards and ultimately sells products at a greater margin.
- 50% improvement in quality
- 28% reduction in field failure rate
- 4.5+ stars for customer satisfaction
- 266.4% IRR, $18.9 million NPV, 11 months payback
SAS difference
SAS empowers manufacturers to unlock the immense potential of AI while accelerating results. Our advanced analytics have robust visualization capabilities and a single platform with an intuitive interface that’s simple to use. SAS scales to meet evolving needs and delivers increased functionality manufacturers need for a competitive advantage.
SAS manufacturing quality software and services help you:
Achieve production and quality improvements
- By applying analytics – including AI, streaming analytics and machine learning – to shop floor and IoT data sources you gain a deeper process understanding than other solutions offer.
Reduce the expenses and inefficiencies of poor quality
- Use analytics to predict and prevent issues that lead to scrap, waste and lost sales. SAS has helped manufacturers improve quality, lower costs and improve customer satisfaction.
Get the right information and answers faster
- Analyze in seconds what could take a half-hour with other software.
Optimize operations to improve yield
- Use trustworthy AI to prescribe the proper setpoints, control limits and operational specifications to improve quality and optimize yield. SAS has helped manufacturers improve yield, with a 1% improvement that translated into $50 million savings.
Find efficiencies across the business
- Easily oversee all aspects of production across the entire business and discover efficiencies that will reduce scrap and energy consumption. SAS has helped customers save valuable time by automating approximately 85% of data cleansing activities.
Deploy models fast
- Use AutoML to accelerate model development and deployment so you can test solutions to costly problems and understand how they will scale.
Enable governance
- Do this through automated data and model lineage and robust model management.
Empower the user
- Gain robust visualization capabilities that enable users of any skill level to discover relationships, trends, outliers and real stories hidden in your data.
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Gain business-critical insights
Integrate and rationalize data from disparate systems and apply AI, ML, deep learning and neural networks to uncover the insights needed to make informed decisions.
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Optimize operations to improve yield
Improve quality and yield using trustworthy AI to prescribe the proper setpoints, control limits and operational specifications. Solve root problems faster and enable more uptime and smoother operations by using root-cause analysis to troubleshoot and correct issues quickly. Analyze in seconds what could take half an hour with other software.
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Quickly respond to issues with the right action
Act quickly and confidently when an issue arises. Analytics, including AI, streaming analytics and machine learning, deliver best-case recommendations that minimize risk at the click of a button.
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Prevent quality issues and reduce costs
Predict and prevent potential failure and detect anomalies in time to identify potential quality issues so you reduce or avoid the costs of poor quality, including scrap, waste and lost sales.