Industry 4.0 Digital manufacturing solutionProactive sensing issue identification analytics

Issue

Approach: proactive sensing

With increasing pressure to identify quality, warranty, and safety issues quickly and limit the scope of service campaigns and recalls, Manufacturers must find innovative ways to distill the vast and disparate data generated in the field.

Proactive Sensing cross-correlates all available structured and

unstructured defect data sources...

...using pre-defined and tested algorithms and risk dictionaries...

...in order to prompt investigators with automatic alerts.

SupplierData

30+ Advanced AlgorithmsMFG Process

Data

60,000+ Line Item Risk Dictionary

Automatic, Prioritized Defect Alerts

Customer Complaints

Regulatory Complaints

WarrantyData

TelematicsData

DealerRepairs

SocialSentiment

Business value: proactive sensing vs. traditional issue detection

Case studies: zinc elusion from fuel hose & alternator failure

By applying advanced analytics across multiple data sources, Proactive Sensing helps identify issues early, thereby limiting the scope of campaigns, reducing warranty repair costs, increasing process efficiency, and improving brand reputation.

Issue: Zinc elusion from fuel hose Original ID Date: April 2013Proactive Sensing ID Date: July 2012Time Savings: 9 monthsTechnique(s) Used: Concept Extraction, Probability AnalysisAnnual Cost Savings: 15% of Recall Spend

Issue: Alternator failureOriginal ID Date: August 2014Proactive Sensing ID Date: August 2012Time Savings: 24 monthsTechnique(s) Used: Event History, Concept ExtractionAnnual Cost Savings: 25% of Recall Spend

Proactive Sensing catches issue (Event History & Concept

Extraction)

24 Month Time Savings

Investigation

Aug 2012 Feb 2013 Aug 2014 Feb 2015

Investigation

Issue emerges in review of warranty

claim data

Campaign Launched

Campaign Launched

3K Fewer Machines Repaired

Issue Identified More Than 1 Year EarlyIssue identified by Proactive Sensing Issue identified by traditional methods

6K

5K

4K

3K

2K

1K

Q1'15 Q2'15 Q3'15 Q4'15 Q1'16 Q2'16 Q3'16 Q4'16

Investigation Investigation

Proactive Sensing catches issue

(Concept Extraction & Probability Analysis)

9 Month Time Savings

Investigation

Jul 2012 Jan 2013 Apr 2013 Oct 2013

Investigation

Issue emerges in manual reviews of

customer complaints

# of Defective Machines Produced

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ContactZhang Tian BingPartner, ConsultingDeloitte ChinaTel: +86 21 6141 2230Email: tbzhang@deloitte.com.cn

Liu HaoDirector, ConsultingDeloitte ChinaTel: +86 21 2316 6294Email: haoliu@deloitte.com.cn

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