A huge range of issues has the potential to delay, disrupt, and derail manufacturing operations. If you can identify these issues at the earliest opportunity, you can maintain an efficient production process.
Traditional monitoring methods struggle to pick up issues such as performance deviations, short-term disruptions, and the failure of critical components such as filtration membranes.
Our approach to predictive solutions provides a proven answer to this problem.
The Challenge
Our predictive maintenance software was tasked with improving the efficiency of a facility’s filtration system. We monitored the existing process from the outset and discovered various issues, including:
Subtle Performance Deviations
The traditional monitoring methods in use prior to MontBlancAI’s involvement were failing to catch minor fluctuations until productivity had already suffered.
Late-Stage Membrane Failures
Defects in filtration membranes were only identified after the membrane cracked and completely failed.
These issues resulted in a halt to production that lasted several days. New membranes had to be ordered, delivered, and replaced, which had a huge impact on the facility’s operation.
MontBlancAI offered a data-driven solution based on predictive maintenance.
The Solution
The facility deployed MontBlancAI’s advanced machine learning models to detect anomalies and promote predictive maintenance faster and more effectively. This almost immediately transformed the way the facility monitored its processes and equipment.
Our non-intrusive predictive maintenance tools delivered immediate visibility without disrupting operations.
Real-Time Process Anomaly Detection
ML models were trained on historical production data to establish normal patterns and control limits. They then monitored live data to detect deviations instantly, alerting teams to subtle disruptions previously overlooked.
MontBlancAI ensured rapid responses to anomalies, preserving process stability and output quality.
Predictive Maintenance for Membranes
Overlaid pressure curves from multiple batches defined standard performance declines. This ensured that the AI could spot early warning signs, including accelerated pressure drops and inconsistent loop behavior—days before failure.
Early detection allowed preemptive maintenance, preventing costly defects and downtime.
The Outcome
After just a few weeks, it became obvious that our AI-powered intelligent manufacturing software had transformed the facility’s operations.
Faster Response to Anomalies
Real-time alerts ensured key personnel could take immediate action, minimizing downtime and disruptions.
Early Defect Detection
Predictive insights were able to identify membrane issues several days earlier than the average, just a few weeks earlier. As a result, the facility was able to avert multiple failures.
Reduced Downtime
Proactive maintenance seriously reduced unplanned stops and raised the overall batch quality.
Enhanced Visibility
Clear, site-wide insights across batches and equipment streamlined decision-making and promoted accountability.
Key Takeaways
The intelligent manufacturing solutions delivered by MontBlancAI revolutionized the facility’s approach to maintenance. Once a cutting-edge predictive maintenance solution was introduced, the team didn’t have to wait until failure before acting.
We learned a lot during the course of this project, including:
AI Uncovers Hidden Risks
We exposed subtle anomalies through real-time ML analysis, proving that seemingly small production issues can have big impacts.
Early Detection Saves Costs
Predictive maintenance caught membrane defects early, slashing downtime and quality risks.
Non-Intrusive Tools Maximize ROI
Our intelligent manufacturing platform’s seamless integration delivered powerful insights without costly system overhauls.
Claim a Significant ROI with Our Predictive Maintenance Solution
We empowered a facility to catch anomalies and defects early, boosting reliability and efficiency.
Our proven platform can do exactly the same for you!
Let MontBlancAI’s AI-driven insights do the same for you. Contact us today to unlock your production’s full potential!
More cases
Explore Additional Success Stories
Optimize Dairy Production
Germany is home to one of the world’s most competitive dairy industries. The small and moderately-sized dairies in the country have to take every opportunity to make their operations more efficient and productive. This is a cost-effective and reasonably feasible way to compete with the large corporations. The pursuit of efficiencies and increased capacity plays a crucial role in this process, but traditional assessment methods are costly, time-consuming, and relatively unreliable.One relatively small dairy approached us due to our reputation for powerful production process monitoring software. The brief was simple: To decide whether optimizing existing equipment or investing in new machinery was the most cost-effective way forward.
UF System Optimization
A major production facility approached us to address the operational issues behind a significant downtime rating. When the facility’s management first assessed the situation, the maximum continuous runtime was a paltry 13 hours before a Cleaning-in-Place cycle was needed. The relatively low uptime witnessed was having a seriously detrimental impact on both operational efficiency and capacity. With the help of MontBlancAI, the team implemented a series of targeted optimizations using, among other things,AI-powered operational intelligence tools. As a result, the facility significantly increased overall efficiency and capacity. Here’s how they did it with the help of our cutting-edge operational intelligence tools.
Enhanced OEE
A manufacturing facility was struggling with filling line inefficiencies, despite seemingly stable monthly performance reports. Frequent, untracked short stops and unclear performance fluctuations were silently eroding productivity. By leveraging MontBlancAI’s advanced production monitoring tools, the facility uncovered and addressed these issues, delivering a remarkable 12.4% increase in Overall Equipment Effectiveness (OEE) within just six weeks. This case study details the challenge, the innovative approach, and the eventual results.
Continuous CIP Validation
Monitoring and validating Clean-in-Place (CIP) processes can be a complex, time-consuming, and costly process, particularly for relatively modest operations. However, production intelligence software powered by AI can make it significantly easier. That’s why a German dairy, processing more than two million liters of milk, turned to MontBlancAI for help. Producing high-quality milk, cream, yogurt, cheese, and butter, the dairy relies on CIP to clean and sanitize equipment and pipelines, ensuring product hygiene, quality, and safety.Was there a way to streamline and enhance the existing CIP processes? Let’s take a look.
