The significance of data and analytics in modern companies has continued to rise. In fact, IDC anticipated that expenses on AI-powered tools like predictive analytics solutions grow from $40.1 billion in 2019 to $95.5 billion by 2022. In this blog, we are going to discuss the use of predictive analytics in manufacturing…

The objective of using predictive analytics is to boost efficiency to understand and analyze complex systems and processes and foresee what will happen next. Technologies like Artificial Intelligence (AI) and machine learning can quickly evaluate a tremendously large volume of data, enabling teams to identify insights at a faster pace. It can benefit an assortment of areas in manufacturing, such as production optimization, quality, maintenance, and waste reduction.

Worldwide market competition, quick innovation and logistics, market instability, and varying regulations need manufacturers to forecast upcoming challenges, conditions, and demands in advance. Predictive analytics gives your manufacturing operations the capacity to derive valuable insight from the compound and varied data you’ve already collected, allowing you to see well beyond the perspective into future opportunities.

Predictive Analytics Solutions for Manufacturing Industry

In this rapidly growing market, manufacturing downtime and the introduction of some inferior products can rapidly damage your reputation and outcomes. Therefore, the manufacturing industries require tools that keep manufacturing processes, infrastructure, and equipment running competently to maximize performance and reduce costs and ad hoc downtime that can disturb production, service, and delivery.

Here you’ll understand what predictive analytics is and why predictive analytics is vital to successful manufacturing.

What is Predictive Analytics?

Predictive analytics exploit the power of historical data with AI and machine learning technology to identify, monitor, manage, and optimize business processes. It also spots and identifies trends, forecast potential concerns, and provides suggestions to improve the process and make performance better. Industrial IoT platforms that empower predictive analytics gather and analyze real-time data to foresee and avoid forthcoming problems at the initial point.

When people talk about manufacturing, the first step to leverage predictive analytics is collecting, storing, and organizing the processed data produced by a variety of machines, devices, and systems within the factory. Generally, factories need almost three to six months of data to use predictive analytics efficiently. Although, this time interval can change depending on the volume of data generated and the targeted issues.

The analytic applications like predictive performance and predictive quality generate data rapidly because production runs on regularly. Sometimes equipment failures can take place, so it can take even months to produce the quantity of data required for specific applications. 

Once accumulated together, the historical data can be used to withdraw insights and make efficient predictions based-on a broad range of variables like line speed, product quality, and more. It includes identifying key relationships between various variables, forecasting variables of interest, and leveraging decision-makers to take early action to lessen waste and boost efficiency.

Today, factories have become ever-more connected, so the predictive analytics technology will turn out as a key part of their digital transformation journey because it can help you become more efficient and competitive and gain more profit.

Predictive Analytics

Why Should Manufacturers Use Predictive Analytics?

It’s obvious that there will be rapid growth in the adoption of predictive technologies in the future. In the manufacturing industry, modern and advanced factories are leveraging predictive analytics to reduce the time to action considerably which saves time, money, material, and speeds up the time of marketing. 

Manufacturers get alerts in advances, such as possible quality failures or unexpected downtime due to machine failure, and enable operators to take corrective action. For example, machine learning can foretell a quality failure that can occur in ten minutes because of dropping line speed and its past consequences, where products do not match quality standards. 

Factories are also using these technologies to identify production trends, resolve issues faster, and handle resources more competently. The capability to recognize potential issues early on with predictive analytics facilitates factories to manage their processes and avoid the costs included material waste, high scrap rates, or downtime.

In the situation of an upcoming skilled labor deficiency, machine learning and predictive analytics technology also have the added benefit of helping manufacturers to attract digital-native staff to engage in their workplace. At a time when many factories find it difficult to employ and preserve talent, the opportunity to work with this cut-throat solution provides a value-added benefit.

How Predictive Analytics Works?

When deploying a predictive analytics solution, firstly collect data from machines and sensors and integrate this data with live operational data, data from MES and ERP systems, and offline quality data. After that, cleaning, merging, formatting, and structuring in the cloud takes place. For example, if one machine notes down the temperature in Fahrenheit and another machine take the temperature in Celsius, then the temperature needs to be converted into a combined metric. 

Based on historical data, machine learning algorithms can find out the behavioral patterns that have earlier lead to problems. If the real-time event starts to pursue one of those problem patterns, then the system can predict the potential result and alert factory managers. Once the operator, engineers, or managers gets alerted, they can rapidly take remedial action and avoid issues from having an important impact. 

Here are the four most important steps that are key components of AI predictive analytics...

Step 1: Access and Explore Existing Data

Step 2: Pre-Process Data With Precision

Step 3: Create and Validate Predictive Models in the Cloud

Step 4: Set up Models and Implement Insights from Predictive Analytics

Predictive Analytics

What Are The Benefits of Predictive Analytics?

As the companies are shifting towards digitalization, manufacturers are under pressure to hold a competitive edge; so many of them often query why they should choose predictive analytics?

Predictive analytics is vital for applications that allow manufacturers to classify problems at their very starting stages, so they resolve them before issues begin to unfold. 

As the return on investment is a key driver of the industry, predictive analytics is competent to deliver insights faster and many factories even estimate measurable cost savings and opportunities for optimization after a few months only. 

Detect Patterns to Calculate Performance 

Predictive analytics go through a large volume of historical data much faster and more accurately than a human. Machine learning technologies are able to spot repeated patterns and further relationship variables. So when you modify these settings, you boost production by 10% without giving up the first-pass yield. 

AI and machine learning can reach to patterns and discover a variety of combinations that help your organization recognize potential efficiency enhancements, forecast issues, and decrease waste. 

Improve Operations in Real-Time

Predictive analytics provides agile real-time insights by evaluating data from past production runs with live production movement. These assessments that convert to predictive and prescriptive analytics both constrain suggestions and alerts to make operations better in real-time. A cloud-native hybrid system joins the power of the cloud with the business stability, allowing factory managers to improve their decision-making process faster.

Trim Down Costs

Quality failures can result in major losses in the product that increases the additional cost of labor and time. Predictive analytics will help factories to find out quality failures and take remedial action quickly to reduce impact and trim down the cost related to waste. Prescriptive analytics can also increase these cost savings by allowing you to repeat your most competent processes more consistently. In addition to this, predictive analytics and situation-based monitoring can help factories decrease unexpected downtime and lost productivity by informing manufactures about probable equipment issues.

Optimize to Precision

Almost all manufacturers are familiar with some Lean Principles that they are following for decades. Sticking to these best practices helps manufacturers attain the utmost production efficiency with the least waste. Predictive Analytics ultimately presents manufacturers with real-world data to help them optimize their operations to reach the precision.

Who In The Manufacturing Industry Can Implement Predictive Analytics?

Predictive analytics can be implemented in the manufacturing industry of approximately every size and any other industry. Some applications might be more appropriate to definite industries than others however since predictive analytics rely on the existing data and models can be used to forecast everything.

Let’s take a look at a few important roles within the factory:

Plant managers – They can benefit from predictive analytics to optimize production and augment contribution boundaries.

Engineers – Predictive Analytics can help engineers to solve problems faster. They can evaluate data faster than ever and utilize analytics-driven procedures and quality recommendations to revise guidelines and processes as well as clear up and root cause problems.

Operators – They obtain alerts about potential failures, so they can take curative action quicker and avoid any downtime related to quality or device failures.

To be more efficient, all you require is the right approach to collect data, like sensors, a place to gather that data and data-skilled staff to recognize what those insights mean.

Predictive analytics in manufacturing

How to Start Using Predictive Analytics?

Meaningful ROI depends on creating the right foundation. To make a predictive analytics solution to be successful in the manufacturing unit, you’ll need the following foundational elements:

A True Source of Data

The data existing within your organization is often complex and disorganized. The different data formats withdrew from ERPs, MES platforms, QMS software, and other basic sources only make it more difficult. If you want to drive real value from your inclusive data, predictive analytics can help you build a single source of certainty. Whether it is operations, quality assurance, or supply chain management, it provides the manufacturing industry a holistic approach to take a dive into your complete data.

Correct and Reliable Data

The correctness and reliability of data impact the capability of any organization to make valuable forecasts. In the manufacturing field, the variety of different data types from an assortment of sources makes data quality management the main concern and that there are apparent relationships throughout your master data. If not, you’ll be incapable of classifying differences or duplicates in your data that can overturn your predictions about all from future demands to employee needs. We can help you to expand dependable quality across your data system to make sure your insights are correct.

A Definite Data Strategy

For predictive analytics and for reporting to present the maximum value, your organization needs a solid data strategy intended around your maximum priorities. Predictive analytics can help to overcome the difference between technology and your business goals, attaining them with the straight route.

predictive analytics Reporting

Centralized Data

With the extent of data available to you, you’ll probably require a centralized data lake for diverse business units to access your collection of data. You are required to consolidate all of the diverse source systems, such as ERPs, MES platforms, etc. into a single reliable source, an achievement you can’t attain without data ingestion.

Accessible Data

When complete data is centralized and validated, your internal BAs and data scientists really require data access. Through custom growth or a cutting-edge solution, you can help to generate dashboards and portals that facilitate your team to inquire questions that authorize them to expect demand, run resources, spot potential risks, and increase your ROI.


There are multiple predictive analytics tools available in the market developed to make Industrial IoT and data analytics more available across the factory ground. Including platforms that enable manufacturers to influence data visualization tools, machine learning, and more. These tools help plant managers, engineers, operators, and quality control managers to discover the most resourceful way to make a product within a robust, secure hybrid cloud-edge environment.

With predictive analytics ability, you’ll be given predictive alerts that permit you to take action quickly to avoid quality and other performance breakdowns. You’ll also make use of interactive dashboards and data discovery that give a picture of real-time performance as well as enable you to examine basic cause analysis to work more efficiently.

If you are interested in making your manufacturing unit more advanced by leveraging the latest technologies like Artificial Intelligence and Machine Learning, implement modern Predictive Analytics Solutions to make it work more efficiently. ExistBI offers consulting services in the United States, United Kingdom, and Europe.


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