Magellan Consulting
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Innovative Advanced Business Analytics Platform

Performance 4.0

Transform Data into Insights & Results

Advanced Industry 4.0 Platform

Performance 4.0 Platform enables operational performance to the next level through Industry 4.0 applications. Easy and rapid to install, uses state-of-the art technology with capabilities such as machine connectivity, data automation, systems integration, streaming analytics, data science & AI applied to industrial processes. Performance 4.0 unleashes improvements of manufacturing operations from overall efficiency, quality control, predictive maintenance, real time management, inventory control and advanced planning & scheduling.
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Industry 4.0 Areas
Industry 4.0 General Results

An advanced machine learning algorithm analyzes process data collected from production systems to provide alerts for early-stage anomalies and system failures to predict product quality

The Internet of Things refers to a technological revolution that aims to connect everyday used items to the world wide web. Predictive maintenance is a focus for the Internet of Things in Industrial Manufacturing

With applications installed on mobile devices that communicate with the systems that industrial automation establishes, it is possible to have access to production data, failure statistics, predictive maintenance schedules, task control, produce reports at the end of the day and much more.

Cloud systems in Industry 4.0 allows for greater efficiency, automation, and data-driven decision making in manufacturing and industrial processes. It can also enable new business models and create new opportunities for innovation.

Intelligent sensors play a crucial role in Industry 4.0 by providing real-time monitoring and data collection of industrial processes, being used in a variety of applications, such as quality control, predictive maintenance, and process optimization.

Industries 4.0 applications commonly implemented in our clients' engagements

OEE Automation

Artificial Intelligence

Systems Integration

Machine Connectivity

Data Automation

Streaming Analytics

Predictive Maintenance

Internet of Things

Performance 4.0 & OEE Optimization

OEE is the most important KPI of any Industrial Manufacturing Process. OEE is a measure of manufacturing efficiency that combines the effects of availability, performance, and quality to provide a comprehensive view of plant-wide productivity. It is calculated as a percentage of ideal production.

Availability

Availability takes into account Unplanned and Planned Stops. An Availability score of 100% means the process is always running during Planned Production Time.

Performance

Performance takes into account Slow Cycles and Small Stops. A Performance score of 100% means when the process is running it is running as fast as possible.

Quality

Quality takes into account Defects (including parts that need Rework). A Quality score of 100% means there are no Defects (only Good Parts are being produced).

Performance 4.0 is key to improve OEE since provides valuable automated data that can be used to improve operations to the next level of performance

Using IoT sensors and machine learning algorithms, Performance 4.0 enables predictive maintenance, allowing organizations to detect and prevent equipment failures before they occur, reducing downtime and improving availability.

Performance 4.0 allows for real-time monitoring of production processes, providing valuable insights into performance and identifying areas for improvement.

By analyzing data from production processes, Performance 4.0 enables organizations to optimize their operations, reducing waste and increasing production speed.

Using AI and machine learning algorithms, Performance 4.0 allows for real-time quality control, reducing the number of defects and improving product quality.

Performance 4.0 provides real-time data, allowing organizations to make informed decisions that optimize production processes, improving OEE and overall efficiency.

Fully Automated Real Time OEE
Fully Automated Real Time OEE
Real Time OEE Components
Real Time OEE Components
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PERFORMANCE 4.0

YOUR NEXT LEVEL OF BUSINESS PERFORMANCE

SMART OPERATIONS INDUSTRY 4.0 PLATFORM
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Performance 4.0 Benefits

Efficiency & Effectiveness

Efficiency & Effectiveness

- Increased efficiency and productivity: advanced technologies can automate repetitive tasks, reduce downtime, and optimize production processes.
- Improved quality control and monitoring: sensors and machine learning algorithms can be used to continuously monitor production processes and identify potential issues before they occur.
- Greater flexibility and customization: with the use of advanced manufacturing technologies, it is becoming possible to produce customized products on a mass scale.
Automation & Digitalization

Automation & Digitalization

- Increased transparency and traceability: Industry 4.0 technologies can provide greater visibility into production processes, enabling companies to better understand how their products are made and track them through the supply chain.
- Cost savings: automation and optimization can lead to reduced labor costs, energy savings and improved resource utilization, which can lead to cost savings.
- Predictive maintenance: with IoT sensors, AI and machine learning, industry 4.0 allows for predictive maintenance of machines and equipment, which can reduce downtime and prolong the lifetime of equipment.

Typical Performance 4.0 results in our engagements

OEE Improvement
Inventory-holding Cost Reduction
Machine Downtime Reduction
Forecasting Accuracy Improvement
Throughtput Increase
Cost-of-quality Improvement