AI has the power to help organizations achieve high-impact results by transforming industrial processes so they can reduce waste and drive sustainable growth.
But while AI continues to reshape the way business is done across industries, many companies in the manufacturing, construction, and oil and gas sectors are under-deploying AI technologies in industrial operations.
As a result, they continue to waste raw materials, overuse energy and water resources, experience too much downtime, and suffer manufacturing defects that negatively affect their margins.
Fortunately, possibilities are virtually endless for organizations that decide to harness AI.
Leverage energy optimization to cut costs
Manufacturers around the globe are grappling with the challenge of cutting energy use, which continues to be among the industry’s highest operating costs and most significant climate change contributors.
The average manufacturing facility uses 95.1 kWh of electricity and 536,500 Btu of natural gas per square foot each year, according to energy consulting company E Source.
Plus, industrial energy use is responsible for almost 30 per cent of all U.S. greenhouse gas emissions, which contribute to global climate change, according to the Energy Star Program, part of the U.S. Environmental Protection Agency and U.S. Department of Energy.
Reduce energy spend
Achieve better overall equipment effectiveness
Optimize asset utilization
Cut greenhouse emissions
Reduce raw material waste by streamlining processes
With superior AI tools, food manufacturers can spot defects within their manufacturing processes and fix them to cut excess by-products.
When this happens, organizations
Minimize production costs
Boost output volume
Improve sustainability by minimizing water use
However, by optimizing water level settings with the latest AI tools, manufacturers can make more accurate estimations to adjust water levels to fit their needs.
Reduce carbon footprint
Advance sustainability efforts
Cut operational spend
Decrease waste and rework costs
Cut unplanned downtime with AI-based predictive maintenance
In construction, the cost of the down unit, including all its associated resources, equals $350 per hour for a total downtime cost of $2,800 over eight hours.
When companies adopt an AI-based platform as part of their predictive maintenance program, they can proactively forecast failures and optimize maintenance.
Most importantly, they can:
Boost operational efficiency
Minimize production losses
Reduce operation and maintenance spend
Advance product conformity to boost batch reliability
Product variability can rack up enormous costs for manufacturing facilities and affect output quality.
While each manufacturer has a different per cent of accepted product variability, it drives waste and production costs up because customers can’t use defective products for intended purposes.
This is why more and more manufacturers rely on sophisticated AI tools to optimize processes that can improve yield.
AI solutions can forecast the quality of output based on prior yield and predicted yields levels, empowering manufacturers to:
Raise production volume
Improve first-pass yield
Enhance asset utilization
Are you harnessing AI in your business?
Your operating systems, industrial processes, sensors and machines store millions of data points that you can extract for a full picture of patterns and interrelationships affecting your operations.
By harnessing these models, you’re helping your operation teams make smarter decisions based on accurate data, rather than intuition or previous achievements.
Moreover, these models will adapt as your business needs evolve over time and help you harness disruptive moments to your advantage.