How AiSight is conquering the enemy of manufacturing companies everywhere

Imagine this scenario: A plant manager stands in his office, watching the production floor beneath bustle with energy. Despite challenging business conditions and growing pressure from competitors producing similar products, the company has continued to thrive. He is confident now that the worst is behind him allowing him to focus on the future growth potential of the company.

Just then, one of the machines on the floor begins to make a loud grinding sound. It bucks and groans and then stumbles to a stop. A pool of hydraulic fluid runs out onto the ground.

Without warning everything just stops.

The entire production line comes to a screeching halt.

Unplanned downtime — the mortal enemy of productivity — has once again reared its ugly head.

For thousands of manufacturing organizations across the globe, this scenario is a painful reality. Unplanned downtime and reactive maintenance can have a significant impact on the ability to meet business goals. But where many people see a problem, some — like the employees at AiSight — see an opportunity.

AiSight founder Matthias Auf der Mauer is one of those visionaries. In 2018, Matthias was working at a world-class automotive manufacturer and saw the way unplanned downtime was impacting their business. As an expert in micro and nano systems, he foresaw a way to use semiconductor technology and advanced algorithms to better predict when machines were nearing failure and help manufacturers anticipate downtime before it happened.

But to make his idea into a reality, they needed to work with the right partners. They needed technology that could provide the best and cleanest data. And that’s where ADI came into the picture.

"What sets AiSight apart is that our solution delivers state-of-the-art analytics while being easy to use and accessible for everybody," said AiSight marketing manager Cecilia Proietti-Franceschilli. "Collaborating with ADI allows us to be on the edge of the market as you get access to the most advanced technologies.”

Recent advances in ADI MEMS technology have allowed AiSight to leverage accelerometer sensors in new ways. One of these applications is for high-fidelity vibration detecting, like those used in condition-based monitoring (CbM).

“For customers who want to predict failure in a system, whether it’s one week ahead or three months ahead, the first step in developing algorithms is data collection,” said ADI engineer Christopher Murphy. “This system enables the highest fidelity and performance of collecting data. The clarity of ADI’s data enables better insight, empowering better success for our customers. It works with both piezo and MEMS sensors, so engineers have the tantalizing opportunity to use both of these sensors in the same system.”

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A great example of AiSight’s product in action is their customer Carl Meiser GmbH & Co. KG. This textiles organization recognized a need for a better maintenance strategy to help reduce unplanned downtime. AiSight helped them install 62 sensors across their most mission-critical manufacturing equipment. Installation took under two days to complete, and when the maintenance team checked the dashboard the next morning, the sensors had already discovered a critical piece of equipment with bearings near failure. The machine wasn’t scheduled for maintenance for months. Instead, the maintenance was pushed up to another planned window, in turn saving the company thousands of dollars.

While ADI technology has helped AiSight make their solution possible, ADI also understands that in today’s hyper-competitive tech environment, moving quickly is essential. With that in mind, ADI can help its customers bring their idea to market faster. ADI’s CN0549 CbM reference design can accelerate time to market. ADI software solutions provide easy access to machine learning tools such as MATLAB or Python-based tools like Tensorflow and PyTorch, which enable customers like AiSight to develop their algorithms more quickly. The result is not only a better product, but getting it into the hands of customers sooner. In the end, everybody wins.

To learn more about the CN0549 platform and how it enables real-time condition-based monitoring, read this article on our open-source, reusable software stack that’s changing the game for CbM.