The Cost of Human Errors in Manufacturing
In today manufacturing environment, even minor errors can lead to significant consequences. For one of our clients, a mid-sized factory specializing in precision components, the challenge was clear: frequent human errors occurring in a short time frame were leading to costly repairs and production delays. These errors not only increased operational costs but also strained the relationship with clients due to delayed deliveries.
The factory manager was spending an excessive amount of time manually rechecking each production stage and monitoring employee activities to identify the root cause of these errors. This manual oversight was not only time-consuming but also prone to oversight, as human fatigue and the complexity of tracking multiple actions simultaneously made it difficult to pinpoint issues accurately.
The implementation of MOHA’s AI-powered solution delivered transformative results for the factory:
Reduction in Errors:
Real-time detection of incorrect actions allowed for immediate corrective measures, reducing the frequency of errors by 40% within the first three months.
Cost Savings:
By minimizing errors and the associated repair costs, the factory saved approximately $150,000 annually in operational expenses.
Improved Efficiency:
The factory manager no longer needed to spend hours manually monitoring operations. Instead, they could focus on strategic decision-making, leading to a 20% increase in overall productivity.
Enhanced Employee Morale:
Employees received real-time feedback on their actions, enabling them to correct mistakes on the spot. This not only improved performance but also boosted confidence and job satisfaction.
Scalability and Future-Readiness:
The solution was designed to scale with the factory’s growth, ensuring it could handle increased production volumes and more complex operations in the future.
The manufacturing industry is under constant pressure to improve efficiency, reduce costs, and maintain high-quality standards. With the rise of global competition, even small inefficiencies can erode profit margins. In this case, the factory’s challenges were rooted in two key factors:
- Increasing Complexity of Operations: As the factory expanded its product lines and adopted more advanced machinery, the complexity of operations increased. Employees were required to perform intricate tasks with precision, leaving little room for error.
- Human Limitations in Monitoring: Traditional monitoring methods, such as manual supervision and periodic checks, were no longer sufficient. Human supervisors could not keep up with the speed and volume of actions occurring simultaneously on the factory floor.
From the end-user perspective (the factory employees), the lack of real-time feedback on their actions meant they were often unaware of mistakes until it was too late. This lack of immediate corrective guidance not only affected productivity but also led to frustration and decreased morale among workers.
Discovering MOHA at SODEC 2024: A Turning Point
The factory’s management team attended the SODEC 2024 trade show, a premier event showcasing the latest advancements in software and technology solutions for industrial applications. It was here that they discovered MOHA Software, a company renowned for its innovative AI-driven solutions tailored to manufacturing challenges.
What stood out to the factory’s management was MOHA’s ability to address specific pain points through cutting-edge technology. MOHA’s booth demonstrated how AI and machine learning could be applied to real-world industrial problems, particularly in the areas of object detection and action recognition. Intrigued by the potential, the factory’s team initiated discussions with MOHA to explore how their challenges could be addressed.
MOHA’s Solution: AI-Powered Action Recognition
After a thorough consultation and on-site survey, MOHA proposed a two-pronged AI-driven solution to address the factory’s challenges:
AI Model for Object Detection
- MOHA implemented an AI model capable of identifying objects and people’s locations through video feeds from the factory’s existing surveillance cameras.
- This model provided real-time insights into the movement of materials and employees, ensuring that each component was in the right place at the right time.
Long Short-Term Memory (LSTM) for Action Recognition:
- MOHA developed an LSTM-based model to analyze and recognize employee actions in real time.
- The model was trained to distinguish between OK (correct) and NG (incorrect) actions, flagging any deviations from the standard operating procedures.
The solution was integrated seamlessly into the factory’s existing infrastructure, minimizing disruption to ongoing operations. MOHA also provided training sessions for the factory’s staff to ensure they could effectively use and interpret the system’s outputs.
The implementation of MOHA’s AI-powered solution delivered transformative results for the factory:
Reduction in Errors:
Real-time detection of incorrect actions allowed for immediate corrective measures, reducing the frequency of errors by 40% within the first three months.
Cost Savings:
By minimizing errors and the associated repair costs, the factory saved approximately $150,000 annually in operational expenses.
Improved Efficiency:
The factory manager no longer needed to spend hours manually monitoring operations. Instead, they could focus on strategic decision-making, leading to a 20% increase in overall productivity.
Enhanced Employee Morale:
Employees received real-time feedback on their actions, enabling them to correct mistakes on the spot. This not only improved performance but also boosted confidence and job satisfaction.
Scalability and Future-Readiness:
The solution was designed to scale with the factory’s growth, ensuring it could handle increased production volumes and more complex operations in the future.
The collaboration between the factory and MOHA Software exemplifies how AI-driven solutions can address critical challenges in the manufacturing sector. By leveraging advanced technologies like object detection and LSTM-based action recognition, MOHA not only solved the factory’s immediate issues but also positioned it for long-term success.
This case study highlights the importance of:
- Understanding the unique challenges of each client.
- Developing tailored solutions that deliver measurable results.
- Building trust through transparency and expertise.
For the factory, the partnership with MOHA was a game-changer, transforming their operations and setting a new standard for efficiency and quality. For MOHA, it was another opportunity to demonstrate the power of AI in solving real-world industrial problems.
As the manufacturing industry continues to evolve, partnerships like this will be crucial in driving innovation and ensuring sustainable growth. MOHA Software remains committed to empowering businesses with cutting-edge solutions that deliver tangible value.