TensorIoT
Maximizing Operational Efficiency With Smart Tech

Automotive manufacturers and suppliers globally are always aiming to enhance their operational efficiency. They’re constantly on the lookout for solutions in line with the principles of Industry 4.0, hoping to bring their operational aspirations to life.

As a leader in smart manufacturing solutions, TensorIoT excels in identifying, designing, and implementing technologies that meet clients’ operational productivity requirements in a straightforward, sustainable, and scalable way. The company addresses common production challenges, including predicting equipment wear and tear, enhancing defect detection, and minimizing resource wastage.

“We deliver scalable smart manufacturing solutions that help customers innovate quickly, automate effectively, and operate sustainably,” says John Traynor, VP and GM of Products and Solutions at TensorIoT.

"The Actionable Insights Provided By TensorIOT’s Smartinsights Helped A Manufacturer Make Data-Driven Decisions, Leading To A 15 Percent Energy Saving And A 17 Percent Improvement In Manufacturing Throughput"

Drawing on their wealth of experience in creating solutions for the manufacturing industry, TensorIoT, an AWS Advanced Consulting Partner, utilizes AI, Machine Learning, data analytics, and modern application and IoT solutions. These tools empower clients to take straightforward but meaningful steps towards boosting their operational efficiency.

Adding Intelligence to the Manufacturing Chain

TensorIoT’s approach is client-centric, starting with a deep dive into the client’s business challenge or objective. This understanding helps clarify the exact business value the client is seeking. From there, TensorIoT works backward to identify the most appropriate technology to meet those needs, which often involves a comprehensive review of the client’s entire manufacturing and supply chain processes.

When pinpointing the most suitable technology to address the client’s problem, TensorIoT also considers how the technology will affect workflows and determines the data sources needed to power the solution.

Once the most beneficial production areas and the right data sources have been identified, TensorIoT integrates a variety of hardware, such as cameras and sensors, into the manufacturing equipment. This integration helps gather valuable insights to guide actions that meet the client’s operational productivity goals.

The collected data is then consolidated and visualized through TensorIoT’s SmartInsights solution. Clients receive a holistic view of their production environment, potentially spanning multiple sites, operating assets at each site, and the attributes and current state of each asset. Through data visualization and machine learning, SmartInsights offers actionable insights that empower clients to make well-informed operational decisions.

TensorIoT’s solutions are designed to provide valuable insights without necessitating a complete overhaul of existing systems. The aim is to optimize production and enhance operational efficiency by focusing changes only on areas where improvements will directly boost performance.

In one instance, TensorIoT worked with a global Original Equipment Manufacturer (OEM) that was seeking a more effective way to schedule production based on comprehensive insights into its supply chain. The client frequently experienced delays or misdirection of critical inventory and parts shipments, resulting in last-minute changes to production schedules.

TensorIoT addressed this challenge by enhancing the client’s visibility into its supply chain. The company incorporated GPS data from inbound shipments provided by the client’s suppliers and their carriers, offering real-time updates on shipment locations and delivery schedules. This wealth of data empowered the client to align production processes with available on-site inventory and future deliveries, allowing for dynamic adjustments to scheduling as fresh information came in.

Incorporating technology into any manufacturing cell necessitates the critical first step of data collection from production equipment. However, the diversity of equipment, stemming from a blend of legacy and modern machinery accumulated over multiple replacement cycles, can pose a challenge.

The skilled TensorIoT technology team manages this issue by leveraging their expertise in navigating the complexities of extracting data from older but still operational machines. Moreover, TensorIoT’s smart manufacturing solutions are compatible with a variety of production environments using any mix of legacy and modern equipment. This compatibility spares clients the expense of machinery replacement and also allows for straightforward adjustments to the project at any stage.

“We triage issues, forecast future phases of the solution, and ensure the system is well architected and capable of working in a customer’s environment for decades to come,” says Traynor.

TensorIoT once collaborated with a global Tier 1 automotive parts manufacturer facing challenges in spotting defects during their manual inspection process. At the beginning of a shift, quality control inspectors were highly proficient at identifying scratches, nicks, and cracks in metal parts. But, as the shift continued, their accuracy decreased due to fatigue, and many defects slipped through the net.

Upon assessing the situation, TensorIoT suggested leveraging computer vision and AI technology to automate the inspection process. They trained a machine learning model capable of detecting defects with impressive accuracy and dependability, effectively addressing the client’s primary concern. The deployment of this solution led to more accurate inspections, fewer false positives (where non-defective parts were flagged as defective), and fewer false negatives (where defective parts were mistakenly marked as good). This technological shift allowed quality control workers to focus on tasks of higher value.

A Strategic Approach to Implementation

To evaluate the feasibility and effectiveness of a solution, TensorIoT employs a “crawl, walk, run” approach. It begins by implementing the solution on a single assembly line or manufacturing cell. If necessary, adjustments are made to ensure the solution’s success before it’s gradually deployed across the facility and beyond, with improvements made as required. Clients have the option to choose either end-to-end or area-specific solutions, granting them greater operational control.

Throughout this process, TensorIoT’s team collaborates closely with clients, ensuring they have a clear understanding of the project’s requirements, strategies, goals, and solutions at every stage.

TensorIoT’s expert-led teams have developed straightforward solutions to address the persistent challenges faced by automotive manufacturers in improving operations. The manufacturing process is a blend of automation and manual labor. Unlike machines, humans are highly unpredictable. Many businesses struggle with staff shortages due to unexpected absences or resignations.

Replacing these workers is a challenging task as new hires require training for specific roles before they can contribute effectively to the production line.

To help a large global client address issues with scheduling and attrition, the TensorIoT team utilized historical attendance, attrition, and other data to develop an advanced model. This model could predict an employee’s attendance based on various factors, enabling companies to schedule additional workers for days when attendance was projected to be low, ensuring they maintained full operational capacity. Similarly, by forecasting attrition, the company could proactively create a pipeline of well-trained, qualified professionals ready to fill vacancies promptly.

Paving a Sustainable Path to Success

Recognizing the increasing emphasis on sustainability across industries, TensorIoT helps clients reduce their carbon footprint without compromising operational efficiency.

One instance involved a manufacturer aiming to adopt sustainable practices and reduce energy usage without affecting their product quality. The solution devised by TensorIoT involved installing sensors on furnaces within their product stamping line to monitor heat distribution.

This data helped identify areas within the furnace that were either excessively hot or cold compared to the rest. As a result, the client was able to adjust the furnace burners to achieve a uniform heat distribution, leading to a five percent reduction in energy consumption without any impact on product quality. Encouraged by the success of this solution, the client decided to expand the project further.

We Deliver Scalable Smart Manufacturing Solutions That Help Customers Innovate Quickly, Automate Effectively, And Operate Sustainably

In another case, the actionable insights provided by TensorIoT’s SmartInsights helped a manufacturer make data-driven decisions, leading to a 15 percent energy saving and a 17 percent improvement in manufacturing throughput.

Amalgamating Empathy with Professionalism

TensorIoT possesses deep-seated expertise in applied technology and remains abreast of the latest tech trends to help clients optimize their operations.

As a global AWS-Advanced Consulting Partner, TensorIoT maintains a skilled and culturally diverse team, each member certified in AWS technology according to their specific roles and responsibilities. As a company, TensorIoT holds multiple AWS competencies, complemented by additional service delivery credentials.

While skills, expertise, and experience are vital when hiring, TensorIoT equally values emotional intelligence, creativity, and a capacity for client empathy. These elements enable the team to approach projects with fresh perspectives, crafting highly tailored solutions for every situation.

Armed with a suite of specific and comprehensive solutions, TensorIoT plans to continue its global expansion, reaching more facilities that need its expertise.

For automotive manufacturers seeking the smart manufacturing solutions of the future, engaging with TensorIoT can offer significant benefits. Beyond simply crafting perfect solutions, TensorIoT is on a mission to assist clients worldwide in bringing their operational visions to life.