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Predictive Analytics in Manufacturing, Manufacturing Analytics, Industrial Analytics

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manufacturing industry

Why Analytics Presents a Game-changing Opportunity for Players in the Manufacturing Industry

Today data and analytics solutions that leverage artificial intelligence, big data, and business intelligence are defining a C-level agenda that forms the basis for all digital transformation initiatives of players in the manufacturing industry. While manufacturers possess huge volumes of unstructured machine data, not all possess the ability to analyze and extract insights from it. But with a powerful manufacturing analytics strategy, manufacturing industry players can tap into this information, converting data into actionable insights to improve decision-making and drive revenue.

Though the data deluge may seem like a challenge, it’s crucial to note that if analyzed properly, data has the potential to become an organization’s most valuable asset. Moreover, the evolution of data is poised to accelerating owing to the evolution of Industry 4.0 and the automation of manufacturing processes. Which means to gain control of this data, businesses that operate in the manufacturing industry must leverage new technologies and advanced manufacturing analytics solutions that turn data to insights. However, the manufacturing industry has traditionally been slow to adopt new technologies and many organizations may find it difficult to fully benefit from investments in digital technologies. This article highlights how manufacturing analytics can improve operational efficiency, productivity, and create a competitive advantage by offering new business opportunities within the manufacturing industry.

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Challenges Facing the Manufacturing Industry

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manufacturing analytics

4 Ways Manufacturing Analytics Can Help Businesses to Optimize Their Operations and Reduce Costs

Businesses that can constantly discover new ways to streamline their operations are successful in the manufacturing industry. Earlier manufacturing companies used to invest a lot of time and resources to examine every single manufacturing process, testing and re-testing innovative ideas and finally implementing changes. However, with the advent of manufacturing analytics, today businesses are able to improve their manufacturing operations more efficiently. With the help of manufacturing analytics, businesses can easily streamline their operations by gaining actionable insights that can further help them to fine-tune their production line. In this article, we have highlighted four ways in which businesses can make noticeable improvements in their manufacturing operations using manufacturing analytics.

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Benefits of Manufacturing Analytics

Production schedule and capacity optimization

When it comes to production scheduling and capacity planning and optimization, most organizations tend to have a hard time. They find it difficult to minimize the discrepancies between their capacity and the demands of their customers. Consequently, most of them are under-utilizing resources or are unable to fulfill customer demand. Manufacturing analytics can help companies in the manufacturing industry to identify, quantify, and prioritize margin improvement opportunities by offering detailed insights into SKU velocity, price band, and segment performance, etc. As a result, manufacturing businesses can improve their production schedule and capacity optimization techniques.

Quantzig’s manufacturing analytics solutions can help you streamline your production processes, improve supply chain efficiency, and increase customer service levels. Request FREE proposal to gain in-depth insights into our portfolio of manufacturing analytics solutions.

Packaging schedule optimization

Manufacturing companies mostly leave their packaging decisions to designers and marketing experts who know how to market and make the products reach to the target customers. Unfortunately, this takes a lot of time and consumes a lot of resources. Manufacturing analytics can help companies to cut down costs by minimizing the number of switches across the production and bottling lines. It can offer predictive scheduling analysis insights that can help companies to gauge resource availability, and resource utilization capacity to make predictions about future workflows.

Predictive maintenance and scheduling

Manufacturing analytics also helps improve production efficiency through predictive maintenance and scheduling. By leveraging advanced data analytics solutions, companies can improve the efficiency of production lines by predicting the number of goods that will pass or fail a quality inspection. Through predictive maintenance and scheduling, companies can precisely identify risks and failures of their assets and can improve their ability to be responsive to the unique pressures on each machine.

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Cost to serve optimization

Manufacturing analytics solutions that leverage advanced data mining techniques, can help companies to gain valuable insights into the actual cost of supplying a specific product to the customer by modeling all logistics activities in the network. Also, it can help businesses to quantify the value of negotiated service levels, shipment exceptions, and other overhead costs. With a robust manufacturing analytics process, businesses can not only gauge the profitability of products, customers, and routes to market but adopt a data-driven approach to decision-making on product mix, service mix and operational changes for each customer.

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Manufacturing Analytics Helped a Leading Steel Manufacturing Company to Improve Product Quality and Enhance Operational Efficiency by 4x- A Quantzig Success Story

The client is a leading European steel manufacturing company that operates its steel mills all across Europe. The company is known for producing electrical steel, hot-rolled, steel plate, and stainless-steel products. The steel manufacturer approached Quantzig to leverage its expertise in offering manufacturing analytics solutions to analyze its production processes and optimize operational efficiency.

Companies in the global steel industry are facing razor-thin margins and are dealing with growing competitive pressures to bring quality products to the market faster and more efficiently than their competitors. Moreover, the constant fluctuations in the price of raw materials have put significant pressure on steel manufacturers. Therefore, companies in the steel industry are looking for better ways to stay ahead of the curve. Consequently, businesses are investing a considerable amount of capital into production process improvement to differentiate their offerings from that of their competitors’ products. To address these challenge manufacturers in the steel industry must leverage manufacturing analytics solutions to identify bottlenecks and optimize steel manufacturing processes.

Our manufacturing analytics experts help companies to tune production operations for minimal cost and risk while capitalizing on data.  Get in touch with them right away!

Business Challenge

The client, a leading steel manufacturer, wanted to produce better quality products that are innovative and reliable. Also, they wanted to reduce operational costs and improve operational efficiency. Furthermore, the client wanted to reduce their reliance on manual tracking systems that hindered their capability to predict machine downtime accurately. Therefore, the steel manufacturing company approached Quantzig to help them affordably capture valuable data and turn them into valuable insights. Also, they wanted Quantzig’s analytics experts to help them devise powerful strategies to improve manufacturing quality, efficiency, and performance.  

Quantzig’s manufacturing analytics solutions help organizations to reduce costs, improve productivity and minimize risk. Request a FREE proposal to gain in-depth insights into our portfolio of analytics solutions.

Solutions Offered and Value Delivered

The manufacturing analytics experts at Quantzig adopted a holistic three-phase approach to help the client tackle their core business challenges. In the first phase of this manufacturing analytics engagement, the experts focused on conducting an in-depth analysis of the client’s datasets to identify different data points such as cost of raw materials and time taken to develop each product. The second phase of the manufacturing analytics engagement revolved around identifying key performance indicators. The final phase of the engagement focused on developing and designing customized manufacturing analytics dashboards to capture real-time data and generate valuable insights.

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The solution offered helped the client to reduce errors in manufacturing processes and focus on improving uptime. Also, the client was able to accurately predict downtime and quickly resolve issues. Consequently, they were able to increase productivity, reduce wastage of raw materials, and improve operational efficiency by 4X.

Benefits of Manufacturing Analytics Solutions 

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Manufacturing Analytics: Key to Drive Significant Improvements Across Business Operations

manufacturing analytics

Manufacturing Analytics: Key to Drive Significant Improvements Across Business Operations

What is Manufacturing Analytics?

Manufacturing analytics is a technique that integrates big data, predictive analytics and industrial internet of things with the manufacturing processes to bring efficiency in the business operations. Manufacturing processes are successful when businesses can streamline their operations. This is where manufacturing analytics can help. Today manufacturers can leverage manufacturing data analytics techniques to examine, test and re-test every single process and implement innovative ideas to make improvements in the business operations. Manufacturing analytics can make manufacturing processes faster and more efficient by offering more focused and actionable insights that can help companies to fine-tune their production line.

Our manufacturing data analytics solution can help you understand the cost and efficiency of your product lifecycle. Request a FREE proposal now to gain better insights into our portfolio of services.

manufacturing analytics

Benefits of Manufacturing Analytics

Decrease downtime

Manufacturers can maximize the operating time of critical assets by leveraging manufacturing analytics solution to anticipate their failure. By utilizing data analytics in manufacturing, businesses can gather historical data (structured and unstructured both) to gain in-depth insights into operations that can’t be assessed with conventional techniques. Using manufacturing data analytics, companies can identify the circumstances that tend to cause breakdown of a machine and monitor input parameters so they can intervene before breakage decreasing downtime. Furthermore, manufacturing analytics can help companies understand how downtime for a single machine can affect the manufacturing chain and how different configurations may improve overall efficiency.

Our analytics experts can help you make better decisions by visualizing how each aspect in your manufacturing chain impacts the final result. Get in touch with them right away.

Gain better insights into machine utilization and effectiveness

One of the major challenges that manufacturers face is wastage of time. While manufacturing chains can be built with efficiency in mind, different factors may play a contributing role in reducing the overall efficiency of the line because of poor installation, misuse, or simply a lack of downtime coordination. By combining existing IoT systems with manufacturing analytics solutions, companies can gain real-time insights into how well their manufacturing lines are operating. Also, it can help in generating actionable insights to help companies realize real improvements in the overall process.

Improve demand forecasts

Any product manufactured today aims to cater the demands that will emerge in the near future. This is the reason why demand forecasts are important from a business perspective. Demand forecasts guide a production chain and help identify the reason between strong sales and an unused inventory. For most companies, forecasts are based on historic values and not on more actionable forward-looking data. By leveraging manufacturing analytics solution, manufacturers can combine existing data with predictive analytics to build a more precise projection of future  purchasing trends.. These insights are derived not just from previous sales data but from how well current manufacturing processes are operating, leading to smarter risk management and less production waste.

Quantzig helps companies to develop effective strategies that can consistently guide them gauge their own need for repairs. Request a FREE demo below to know more.

Better warehouse management

Storage is generally the most overlooked aspect of the manufacturing process. Every stage is important when products are ready to be shipped especially in a world that is increasingly embracing zero-inventory models to reduce overstock scenarios. This is where warehouse management is important. Establishing an efficient warehouse management system can further improve product flow management, and improve business operations, as well as the bottom line. Manufacturing analytics framework makes it easier to understand how to improve your inventory and manage your warehouses better. This can, further, help in improving manufacturing KPIs and processes. By incorporating a robust manufacturing analytics solution companies can build a more granular understanding of how their production line operates, and how they can streamline it to avoid unnecessary costs

Why Quantzig?

Manufacturing leaders today are visionaries, pioneering increasingly efficient methods to produce and move physical goods while thinking beyond cost savings, productivity, and risk reduction. Future survival needs manufacturers to become nimble and analytics driven. This can help organizations minimize risk and seize opportunities through actionable operational insights and confident decision making. Manufacturing analytics solutions from Quantzig can help companies to fine-tune their production operations for minimal cost and risk while capitalizing on data as an asset that can further help them deliver innovative services and quality products. We, at Quantzig, deliver proven value and help leading companies unlock the immense potential of their digital transformation through our customized manufacturing analytics solutions.

Want to learn more about how manufacturing analytics can help you predict maintenance issues and prevent breakdowns? Request for more information now!!

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4 Major Impediments That the Manufacturing Industry Must Tackle

Despite the common conjecture that the manufacturing industry in the U.S. is taking a downturn, it still produces over 18 percent of the world’s total goods. This clearly goes out to prove that despite several hindrances, the manufacturing industry is on its way to resurgence. This can be attributed to the advent of new technology and lean manufacturing processes combined with a strengthening economy. However, there is no time for players in the U.S. manufacturing sector to unruffle, they must devise a new game plan to tackle challenges that come their way and continue their upward momentum.

Challenges facing the manufacturing industry

Shortage of skilled labor

The fact that the baby-boomer generation is entering into the retirement stage has taken a major hit on manufacturing companies. But the good news is that with the advent of technology, players in the manufacturing industry can gradually replace human labor with machines and employ candidates with a variety of other skill sets including proficiency in mathematics and analytics. The largely unskilled, trainable workforce that once made up a major portion of the employees in the manufacturing industry can now be replaced with automation and machine sensors. Moreover, AR and VR technologies are now making it easier for companies in this sector to train the workforce on the job while cutting costs.

Rising competition

Manufacturers in the U.S. face competition from all corners of the globe. In the recent year, China has proved to be one of the biggest competitors for the U.S. manufacturing industry as they are known to produce products for a fraction of the price that it would otherwise cost to make those same products stateside. Players in the manufacturing industry need to make their value known in order to combat global competition. Companies in this sector must constantly leverage the expertise of their people, improve their speed to market, undertake better innovation, and ensure supply chain efficiency, all this at the minimum possible cost.

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demand and capacity planning

Manufacturing Technology Trends: What’s New in 2018?

The face of manufacturing technology is gradually being transformed by the digital transformation of manufacturing, ongoing convergence of IT and OT, and the usage of IoT in combination with several other technologies. Just like how industrial revolution had an impact on manufacturing, now, digital transformations are all set to bring big changes in the manufacturing landscape. Manufacturing companies are now able to shift from traditional mass production to customized production with the help of advanced technologies. Furthermore, the highly dynamic consumer expectations and the advent of connected devices and platforms are driving the persistent digitization of the manufacturing process. Also, sustainable alternatives will replace existing processes, and manufacturing companies will soon find it difficult to avoid the IndRequest Solution Demoustrial Internet of Things (IIoT). Here are some of the manufacturing technology trends to watch out for in 2018: 

Green manufacturing

Manufacturing companies are now pushing for green, sustainable alternatives rather than traditional manufacturing. Green initiatives are becoming essential components for saving money for manufacturing companies. The availability of raw materials and resources becoming tighter each day is giving rise to a circular economy.  In a circular economy, recycled and reusable materials can be processed and used to reduce the cost of manufacturing items. Green manufacturing is one of the manufacturing technology trends that will grow in importance this year as green initiatives are pushing consumers toward companies that embrace sustainable motives.

Off-site IT investments

In-house IT departments are becoming obsolete in the manufacturing industry.  Cloud-based technologies are gaining more momentum and major manufacturing companies are planning to increase their investments in customer relationship management (CRM) tools. With the growing need to enhance cybersecurity, more companies will outsource their manufacturing technology and IT services to third parties who provide additional, value-added services. This change will also help small and medium-sized businesses to easily access the latest technologies with reduced investment requirements.

Customization in inventory management

Traditional inventory management systems will soon become outdated in the manufacturing industry. Companies will soon revamp their manufacturing technology and inventory management using advanced computer analytics systems to manage inventory in real-time. This has a variety of benefits including reducing overhead and improving operations, eliminating shrinkage due to theft, and avoiding damages and errors during shipping.

IoT and industry 4.0

IoT is rapidly becoming an indispensable element in manufacturing technology. With the help of this connected technology, manufacturing companies have streamlined and simplified various processes.  IoT in manufacturing technology can provide real-time inputs and alerts with which companies can easily detect defects or damaged goods. Such simple yet critical implementations of IoT helps reduce cost and wastage. Industry 4.0 is the current trend of automation and data exchange in manufacturing technology. This has given rise to smart factories in which cyber-physical systems evaluate the physical processes of the factory and make decentralized decisions.


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Customer data management

Top 3 Benefits of Manufacturing Analytics for Manufacturing Companies

Globally, the manufacturing industry has been subjected to a plethora of changes due to which manufacturing companies have started squeezing every asset for maximum value. One of the most common themes gaining traction in the manufacturing industry is the value that statistical processing brings to the overall manufacturing process. This process of statistical data processing is often referred to as manufacturing analytics. In our experience, a common belief among system integrators and end users is the fact that the ability to assess manufacturing data with complex algorithms has the potential to provide competitiveGet More Info_QZ advantage through increased efficiency and reduced dependency on staff experience.

The process of gathering data had started years back in regulated industries like pharmaceutical and healthcare and others soon followed suit. The trend of adopting manufacturing analytics is fueled by the idea that knowing what happens in the manufacturing process, can help manufacturing companies to diagnose and troubleshoot problems. Initially, manufacturing analytics was only used to study macroeconomics and demographics. But now, it is being used to identify patterns and correlations between unstructured data sets.

Here are some of the advantages of using manufacturing analytics for manufacturing companies:

  • Correlate data related to different process variables

While analyzing an unstructured data set, you may think that the data is not related to each other. However, with the help of advanced IT tools, data scientists can discover hidden correlations between different data sets. The information gathered is an integral part of the overall manufacturing analytics process since it can be leveraged for accurate and effective production management.

  • Better control manufacturing processes

Once a common pattern is established between the data sets, manufacturing analytics tools that were used to identify the pattern can now be utilized in real-time for process control purposes. Using effective manufacturing analytics tools can help manufacturing companies to improve both production efficiency and product quality. Since early detection gives the scope for timely action, manufacturing companies can avoid instances of plant downtime and boost efficiency.

  • Leverage personal knowledge

When we say, “leverage personal knowledge”, some of you might think how is that even relevant for manufacturing processes as the entire production cycle follows a preset model. However, with the help of manufacturing analytics, companies can gain a measurable representation of what the staff already knows from experience. Being able to formally represent such insights, will help manufacturing companies to reduce the impact of risks related to staff turnover. With the aid of manufacturing analytics, companies can effectively transform the insights gained from personal experience and leverage it to control processes independently.

Though we’ve spoken at length about the numerous benefits of manufacturing analytics, a key thing to note here is that manufacturing companies must invest heavily in technologies such as hardware systems and software suites. And that’s not all, companies must also invest in new people who can either be a part of the existing structure or external system integrators.


Quantzig is a pure-play analytics solution provider, specializing in offering solutions for manufacturing analytics, marketing analytics, predictive analytics, big data analytics, and many more. To know how our manufacturing analytics solutions can help you:

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Supply chain visibility and root cause analysis for OTIF failures across inbound and outbound supply chains

In the retail and CPG landscape, leading manufacturing firms have started shifting towards a fashion-oriented environment to meet the altering preferences of the consumers. To reach out to the right target audiences in an agile and seamless manner, it becomes indispensable for leading retail organizations to ensure that they have a robust supply chain. Supply chain analysis helps companies improve and strengthen their supply chain by making data readily available to the stakeholders. Also, ensuring better supply chain analysis helps organizations streamline and reshape their prevailing supply chain processes and effectively track and monitor supply chain activities.

In every organization, the first and the foremost preference for manufacturers is to gain better visibility into the interruptions that could affect product delivery. With years of expertise in offering a plethora of solutions, Quantzig’s supply chain analysis helps the client gain actionable insights on supplier inventory levels, efficiently meet the compliance issues, and devise a robust disaster recovery plan.

Mitigate risks and stay on top of demand with Quantzig’s supply chain analysis solutions. Request a FREE Demo to know more.

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The Business Challenge

A renowned sports goods, apparel, and accessories manufacturer with supply chains spread across 20 countries was facing a predicament in identifying the major reasons for failures in inbound and outbound deliveries. The client wanted to understand delivery levels across four channels such as the wholesale, retail, franchise, and WHS monoband. Moreover, the client wanted to understand the factors leading to inbound delays, outbound delays, and the impact of inbound delays on outbound deliveries. By leveraging Quantzig’s solution, the client wanted to assess the major factors responsible for the OTIF failures in the inbound and outbound supply chain.

The primary objective of this engagement was to optimize its supply chain by identifying the best suppliers and maximize OTIF levels for outbound deliveries.

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Solutions Offered and Value Delivered

To address the potential challenges in terms of OTIF failures, the client approached Quantzig’s team of supply chain analysts. Quantzig’s team of supply chain analysts created a dictionary comprising in-bound and outbound data based on the client’s requirements. Furthermore, the client carried out assumption and exclusion criteria technique for data cleansing, including missing value treatment, outlier detection, and elimination and hierarchy for interim process dates. The client further crafted a dashboard to visualize the end-to-end supply chain process.

Benefits of Inbound and Outbound Data Analysis

  • Gained actionable insights on the exploratory and univariate analysis of inbound data
  • Gained analysis of departure for POs from ports revealed the two ports responsible for the highest delays
  • Gained more insights into the supply chain activities in terms of the delays in the shipping through CFS mode
  • Understood the highest delay duration from the shipment (factory to the warehouse)
  • Identified the wholesale channel that had the lowest out-bound OTIF levels
  • Identified the delay for OTIF deliveries
  • 86% of the products were delivered with just one-day delay in terms of the outbound lead time

Inbound and Outbound Data Analysis Predictive Insights

  • Identified the duration between the PO arrival at the destination port and reaching the warehouse
  • Created a robust linear regression model to understand the impact of each contributing factor
  • Identified the shipment type and port of departure that had a significant impact on the delay
  • Created a simulator to predict inbound delays
  • Identified the inbound logistics, warehouse storage, and manufacturing issues responsible for the cause of the delay
  • Identified the interim process and conditions with highest delay probability to maximize out-bound OTIF

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customer segmentation analytics

Big data analytics and manufacturing planning delivers USD 23 million savings for electrical components manufacturer

Business Challenge: Dependence on traditional market segmentation strategies that did not yield expected returns and profits

A global electrical components manufacturer wanted to improve its customer segmentation in order to achieve better revenue and profits.

Situation: Manufacturing plan incoherent of vast amount of customer data

The client had access to huge volumes and variety of customer data, but was unable to utilize them effectively in order to develop manufacturing plans as per changing customer segments and their requirements. This was resulting in lower than expected returns from the manufacturing investment.

Solution/Approach: Big data analytics and predictive modeling to map demand to manufacturing

We integrated data from various silos, and mapped them against client’s existing manufacturing strategies through big data analytics, to identify gaps and create a better manufacturing plan based on customer segmentation. We also developed a predictive model for assessment of profitability levels of customers and segment them accordingly.

Impact: Improved ROI by USD 23 million

The client was able to understand and anticipate the demand from various customer segments and created a more demand centric manufacturing policy. This reduced stock outs and wastage, and improved the ROI by USD 23 million.