Unplanned downtime in manufacturing costs firms up to a trillion dollars annually. Time that materials spend sitting on a production line is lost revenue. Even just 15 hours of downtime a week adds up to over 800 hours of downtime yearly. The use of Internet of Things or IoT devices can cut this time down by providing details of machine metrics. However, IoT predictive maintenance is challenged by the lack of effective, scalable infrastructure and machine learning solutions. IoT data can be the size of multiple terabytes per day and can come in a variety of formats. Furthermore, without any insights and analysis, this data becomes just another table.
The KPMG Databricks IoT Accelerator is a comprehensive solution enabling manufacturing plant operators to have a bird’s eye view of their machines’ health and empowers proactive machine maintenance across their portfolio of IoT devices. The Databricks Accelerator ingests IoT streaming data at scale and implements the Databricks Medallion architecture while leveraging Delta Live Tables to clean and process data. Real time machine learning models are developed from IoT machine measurements and are managed in MLflow. The AI predictions and IoT device readings are compiled in the gold table powering downstream dashboards like Tableau. Dashboards inform machine operators of not only machines’ ailments, but action they can take to mitigate issues before they arise. Operators can see fault history to aid in understanding failure trends, and can filter dashboards by fault type, machine, or specific sensor reading.
Talk by: MacGregor Winegard
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