Manufacturing Intelligence
Go Beyond What Happened. Understand Why.
Manufacturing operations generate enormous volumes of data, but having more information does not necessarily lead to better decisions.
A change in yield, an increase in material usage, or a decline in equipment performance tells you something happened. Understanding why requires connecting those outcomes to the materials, equipment conditions, production events, and operating decisions that preceded them.
Relevant Stats applies advanced analytics to computational plant models, uncovering meaningful relationships between manufacturing conditions and performance.
Our objective is simple: turn manufacturing data into a better understanding of the process and use that understanding to improve operational and financial results.
Material Usage and Yield Intelligence
Where is material being lost, and what is driving that loss?
For many manufacturers, raw materials represent one of the largest components of production cost. Relatively small differences in material usage, giveaway, waste, or finished-product yield can have significant financial consequences.
Relevant Stats connects material consumption with production runs, product characteristics, equipment conditions, and process measurements to provide a deeper understanding of material performance.
Our analytical capabilities include:
Actual versus expected material consumption
Material usage variance by product, line, run, and shift
Giveaway, yield loss, scrap, and rework analysis
Relationships between process conditions and material losses
Financial quantification of material performance opportunities
Rather than simply identifying that consumption exceeded expectations, we help manufacturers investigate the operating conditions associated with the variance.
The goal is to make material losses understandable, measurable, and increasingly preventable.
Process Variation and Stability
What makes one production run perform differently from another?
Manufacturing processes operate under constantly changing conditions. Raw material properties vary, equipment behavior changes, environmental conditions shift, and operating adjustments affect the final outcome.
Traditional statistical reporting can identify variation without necessarily explaining it.
Relevant Stats combines statistical process control, multivariate analysis, and manufacturing context to investigate the relationships influencing process stability.
We examine performance across comparable production conditions, helping identify patterns associated with stable operations, unusual variation, and recurring production problems.
This enables manufacturers to distinguish normal process behavior from meaningful changes and focus improvement efforts on the conditions most closely associated with desired outcomes.
Manufacturing Performance Diagnostics
Why is the operation performing the way it is?
Metrics such as OEE, throughput, downtime, and production efficiency describe aspects of manufacturing performance.
But a performance metric is not an explanation.
Relevant Stats connects equipment performance with the broader manufacturing process, including product changes, material characteristics, operating conditions, production interruptions, and quality outcomes.
By examining those relationships, we help manufacturers understand the conditions associated with lost production capacity, reduced throughput, and inconsistent performance.
The objective is not simply to calculate another KPI. It is to understand what influences that KPI and which factors may be within the operation's control.
Predictive Analytics and Intelligence
What can we anticipate, and what should we do differently?
Once manufacturing data is properly contextualized, more advanced analytical techniques become possible.
Relevant Stats develops specialized models using statistical methods, deterministic process logic, machine learning, and other techniques suited to the manufacturing problem.
These models can help identify emerging changes in process behavior, estimate the likelihood of undesirable outcomes, and evaluate potential opportunities for improvement.
Where models have been appropriately validated, their findings can support operating recommendations, targeted investigations, and earlier intervention.
Our approach emphasizes interpretable findings, appropriate model validation, and practical application in the manufacturing environment.
Artificial intelligence is one tool in this process. Understanding the manufacturing operation remains the foundation.
Analytics That Support Real Decisions
The value of intelligence is realized when someone can act on it.
Relevant Stats delivers analytical findings through applications designed around the people making manufacturing decisions.
Depending on the operation, this may include real-time performance monitoring, automated exception detection, statistical visualizations, scheduled analysis, operational reporting, and custom interfaces.
Plant managers need to understand where improvement opportunities exist. Process engineers need to investigate the conditions behind performance changes. Operators need timely information that supports the decisions they make during production.
Our systems are designed to make the appropriate information available to each of them without introducing unnecessary complexity.
Start with the Problem Worth Solving
Every manufacturing operation has opportunities hidden within its process data.
Relevant Stats works with manufacturers to identify meaningful operational challenges, establish the necessary production context, and develop analytical models targeted at improving measurable results.
An initial project may focus on material losses, yield variation, or an unexplained performance problem. The same underlying plant model can then support additional applications as the operation's analytical needs evolve.
Better context. More relevant analysis. Better manufacturing decisions.
Let's Examine Your Operation
Contact Relevant Stats to discuss where deeper manufacturing intelligence could create value in your operation.