Sight Machine Case Studies Digital Transformation of Essex Furukawa with Sight Machine

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	Digital Transformation of Essex Furukawa with Sight Machine Sight Machine

Digital Transformation of Essex Furukawa with Sight Machine

Sight Machine

Technology Category	Analytics & Modeling - Machine Learning Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries	Electrical Grids Equipment & Machinery
Applicable Functions	Maintenance Quality Assurance
Use Cases	Predictive Maintenance Visual Quality Detection
Services	Testing & Certification
Challenge	Essex Furukawa, the world’s largest manufacturer of magnet wire/winding wire, faced a significant increase in demand due to the rapid shift of global automakers towards electric power. The company needed to maintain its market leadership by increasing throughput and uptime while delivering high-quality products. The challenge was to meet the growing demands without compromising the quality of their products. The magnet wire they produce for electric vehicle motors must meet exacting standards to withstand years of severe stress, including high heat, high electrical current, and fast switching frequencies. Essex Furukawa leadership recognized the need for a digital transformation of their manufacturing plants to collect and analyze production data for predictive maintenance and continuous operational optimization. Read More
About Customer	Essex Furukawa is the world’s largest manufacturer of magnet wire/winding wire, which powers motors, including the motors that power electric vehicles. As global automakers began rapidly shifting their production to focus on electric power, Essex Furukawa faced significantly increased demand. To maintain its position as market leader, Essex Furukawa leadership sought to digitally transform its manufacturing plants to increase throughput and uptime while delivering the high-quality products for which they are known. The company's growth depended on the ability to increase production without affecting quality. Read More
Customer Name	Essex Furukawa Read More
Solution	Essex Furukawa partnered with Sight Machine to begin the digital transformation of their manufacturing plant in Torreon, Mexico. Sight Machine, a Microsoft partner, was chosen for its unique ability to turn all production data into a common data foundation for manufacturing operations and analysis. Essex Furukawa uses Microsoft Azure as its secure, intelligent, and scalable cloud platform. Sight Machine on Microsoft Azure provides Essex Furukawa with a single, trusted, and dynamically updated view of production, enabling them to track Overall Equipment Effectiveness (OEE) across all plants and to greatly improve throughput with no impact on availability or quality. Sight Machine also developed analytics models focused on improving quality. The system recommends ways to improve quality and validates the magnitude of improvements to ensure worthwhile results. The model is continuously retrained using real-time streaming data for optimal effectiveness. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Machine Learning

Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Electrical Grids

Equipment & Machinery

Applicable Functions

Maintenance

Quality Assurance

Use Cases

Predictive Maintenance

Visual Quality Detection

Services

Testing & Certification

Challenge

Essex Furukawa, the world’s largest manufacturer of magnet wire/winding wire, faced a significant increase in demand due to the rapid shift of global automakers towards electric power. The company needed to maintain its market leadership by increasing throughput and uptime while delivering high-quality products. The challenge was to meet the growing demands without compromising the quality of their products. The magnet wire they produce for electric vehicle motors must meet exacting standards to withstand years of severe stress, including high heat, high electrical current, and fast switching frequencies. Essex Furukawa leadership recognized the need for a digital transformation of their manufacturing plants to collect and analyze production data for predictive maintenance and continuous operational optimization.

About Customer

Essex Furukawa is the world’s largest manufacturer of magnet wire/winding wire, which powers motors, including the motors that power electric vehicles. As global automakers began rapidly shifting their production to focus on electric power, Essex Furukawa faced significantly increased demand. To maintain its position as market leader, Essex Furukawa leadership sought to digitally transform its manufacturing plants to increase throughput and uptime while delivering the high-quality products for which they are known. The company's growth depended on the ability to increase production without affecting quality.

Customer Name

Essex Furukawa

Solution

Essex Furukawa partnered with Sight Machine to begin the digital transformation of their manufacturing plant in Torreon, Mexico. Sight Machine, a Microsoft partner, was chosen for its unique ability to turn all production data into a common data foundation for manufacturing operations and analysis. Essex Furukawa uses Microsoft Azure as its secure, intelligent, and scalable cloud platform. Sight Machine on Microsoft Azure provides Essex Furukawa with a single, trusted, and dynamically updated view of production, enabling them to track Overall Equipment Effectiveness (OEE) across all plants and to greatly improve throughput with no impact on availability or quality. Sight Machine also developed analytics models focused on improving quality. The system recommends ways to improve quality and validates the magnitude of improvements to ensure worthwhile results. The model is continuously retrained using real-time streaming data for optimal effectiveness.

Impact #1	The deployment of Sight Machine on Microsoft Azure has provided Essex Furukawa with a single, trusted, and dynamically updated view of production. This has allowed them to adopt a unified method to track Overall Equipment Effectiveness (OEE) across all plants and to greatly improve throughput with no impact on availability or quality. The system has also developed analytics models focused on improving quality. The recommendations from these models have resulted in significant efficiency improvements. The successful deployment in their Mexico manufacturing plant led to the decision to use Sight Machine as the manufacturing productivity platform for its plants in the United States, China, Germany, Serbia, Canada, and Malaysia. The platform has enabled rapid experimentation, allowing the company to make adjustments on the line and measure the impact very quickly.

Impact #1

The deployment of Sight Machine on Microsoft Azure has provided Essex Furukawa with a single, trusted, and dynamically updated view of production. This has allowed them to adopt a unified method to track Overall Equipment Effectiveness (OEE) across all plants and to greatly improve throughput with no impact on availability or quality. The system has also developed analytics models focused on improving quality. The recommendations from these models have resulted in significant efficiency improvements. The successful deployment in their Mexico manufacturing plant led to the decision to use Sight Machine as the manufacturing productivity platform for its plants in the United States, China, Germany, Serbia, Canada, and Malaysia. The platform has enabled rapid experimentation, allowing the company to make adjustments on the line and measure the impact very quickly.

Benefit #1	Greatly increased throughput without loss in quality or availability
Benefit #2	Developed solutions to improve quality
Benefit #3	Sight Machine is being scaled to Essex Furukawa plants worldwide

Benefit #1

Greatly increased throughput without loss in quality or availability

Benefit #2

Developed solutions to improve quality

Benefit #3

Sight Machine is being scaled to Essex Furukawa plants worldwide

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Overview

Digital Transformation of Essex Furukawa with Sight Machine

Operational Impact

Quantitative Benefit