Process yield optimisation — Plastics
Models that recommend set-points to lift yield and cut scrap. Delivered for a plastics client in Surat.
- Location
- Surat
- Year
- 2020
- Duration
- 9 weeks
- Team
- 5 engineers
- +6.8%
- yield
- −43%
- scrap
- 13,719
- batches modelled
The challenge
Existing vendors had delivered pieces of a process yield optimisation system, but nobody owned the integration and the pilot had stalled.
What we built
We ran a two-week discovery sprint, then built and fielded the system end to end on XGBoost, Bayesian optimisation and OPC UA, with operator training and an SLA.
Delivery timeline
Phase 1
Discovery sprint and site survey
Phase 2
Prototype built and tested in the Motera lab
Phase 3
Pilot on site with before/after measurement
Phase 4
Scale-out, training and handover
Highlights
- Integrated with existing PLC, ERP or GIS systems — no rip-and-replace
- Documentation, drawings and source handed over at close
- Remote monitoring and over-the-air updates included
- Operator training delivered in Gujarati, Hindi and English
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