Maximizing value at every stage of production

challenges in manufacturing

Manufacturers aim to deliver the highest quality at the lowest cost during the production or assembly process. At the same time regulations need to be met and worker safety must be guaranteed at all times.

A wide range of assets, from halls and machines, to materials and products must be closely monitored for potential hazards, defects, and quality issues. Physical inspection of all this requires a vast amount of deep knowledge due to product variables and ever-changing circumstances on factory floors. If manufacturers fail to detect issues, they are unable to take immediate remedial action resulting in loss of margin, or worse. 

Digital inspectors for physical inspection in manufacturing can prevent problems from escalating or happening in the first place. In most factories, proprietary knowledge has accumulated in the brains of a small group of domain experts.

Years of experience and fine-tuned skills are almost impossible to replace, but inevitably your most experienced staff members will reach their retirement age. Protecting their knowledge by transferring it to BrainMatter as learning examples and detection skills, combined with actionable business rules is crucial.


Digital inspectors for manufacturing

Perceive Decide Respond

Digital inspectors automate the recognition of assets, the interpretation of their current state and initiates actions to resolve issues. 

BrainMatter streamlines the process of automating tasks that require a level of knowledge, experience and skill.

It eliminates manual processing with the attendant risk of human error, ensuring inspections are undertaken at an optimal frequency and in compliance with regulatory requirements.

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  • Ensure physical assets are functional, in place and undamaged
  • Keep track of materials, tools, people and vehicles in real-time
  • Control picking, sorting and counting on production lines

Quality control

  • Assess product quality for optimal pricing and customer satisfaction
  • Prevent breakdowns due to product defects on the line
  • Automatically check the assembly of multiple part products against the norm

Safety & Security

  • Monitor compliance to safety regulations, social distancing and tool usage
  • Move domain experts from factory floors to offices, while increasing performance
  • Automate seal and packaging checks to prevent accidents

use cases for manufacturing

  • Automate assembly checks
  • Conveyor belt inspection
  • Item recognition, counting, picking and sorting
  • Remote machine monitoring
  • Automated product quality inspection
  • Change and anomaly detection
  • Updating digital twins with the current reality
  • Normative process checking
  • Signal dangers before workers do
  • Seal and package inspection
  • Object tracking
  • Robot Vision
  • Pollution detection 
  • Automated video surveillance

Digital inspectors in action: Tata Steel

Tata Steel in IJmuiden produces sheet metal, sold as large coils. Inevitably there are a variety of defects in the material from minor to severe, caused by imperfections in the production process on the steel surface. These defects influence the overall quality and pricing of a coil and severe defects can even damage the production machines of the customer or of Tata Steel. Shutting down the machine to prevent breakage is a costly exercise that happens on a regular basis.

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