Optimizing Multi-Stage Manufacturing Productivity

Background

Our client operates a complex multi-stage manufacturing process, involving various chemical reactions. Lacking holistic visibility across all production phases made it difficult to align material flows, causing bottlenecks and stoppages that constrained output.

The Challenge

Without aligning inputs to real-time demand at each stage, our client struggled with:

  • Mismatched supply and demand between process steps
  • Lost production due to overflow incidents
  • Overall process inefficiency and limited total output

 

The Solution

Analyzing data from over 350 sensors, our AI platform developed predictive models forecasting material requirements.

With 60-minute demand predictions and timing guidance, operators can now seamlessly synchronize flows across all production stages.

The Results

Leveraging DataDudes AI optimization, our client achieved:

  • 45% decrease in overflow stoppages
  • 8% increase in production output
  • Major efficiency gains

By enabling end-to-end visibility and system alignments, we unlocked greater process efficiency and productivity.

 

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