Project Details
[Return to Previous Page]Smart Manufacturing: AI Solutions for Equipment Performance Improvement
Company: Dana Incorporated
Major(s):
Primary: IE
Secondary: CMPSC
Non-Disclosure Agreement: YES
Intellectual Property: YES
Problem Statement: Dana Incorporated, a Tier 1 automotive supplier with over 120 years of manufacturing expertise, is committed to Operational Excellence and Continuous Improvement across its global production network. With 90 manufacturing facilities worldwide, Dana faces the challenge of leveraging Industry 4.0 technologies to enhance equipment effectiveness, process reliability, and throughput optimization. The objective of this project is to design and implement an AI-driven analytics framework capable of ingesting high-volume production and process data to identify bottlenecks, predict equipment performance trends, and recommend data-driven corrective actions. This solution should be scalable, repeatable, and integrate seamlessly with existing manufacturing execution systems (MES) and industrial engineering workflows. Deliverables may include an AI agent, standardized prompting protocols, and a user-friendly interface for manufacturing and industrial engineers to access actionable insights. Benefits: Enhanced Operational Efficiency Reduces latency between data acquisition, root cause analysis, and implementation of corrective actions. Standardized Process Optimization Establishes a unified, data-driven methodology for improving Overall Equipment Effectiveness (OEE) across all plants. Cost Reduction Accelerates identification of production bottlenecks, minimizes unscheduled downtime, and reduces overtime costs through proactive maintenance and optimized scheduling. Scalability and Consistency Provides a repeatable framework for enterprise-wide deployment, ensuring consistent performance analytics and continuous improvement initiatives. Project Requirements: AI (Co-pilot) based solution with the following high-level functions: Import Production Dana from the “Ignition” Manufacturing Execution System, utilizing the standard format as exported by Ignition. Analyze and group data according to Dana direction (Machine Class, Equipment supplier, product type, equipment type, etc…) Provide insights based on Dana direction (Worst of Worst performers, Best of Best performers, Highest Uptime, Highest Downtime, etc…) Data output should have the ability to be filtered (exported to a spreadsheet friendly format) Create an Agent that can be imported into Dana’s co-pilot environment (Co-pilot studio, Co-pilot chat) Stretch Targets: Bottleneck analysis Provide insights as to what each department bottle neck is by site Corrective Action Insights Provide recommendations on corrective actions based on the failure modes discovered through data analysis4. Project Deliverables: Implement requirements via a Co-pilot AI agent that can be imported into Dana’s environment. Base scope of project is to complete the requirements listed. Stretch targets focus on specific Bottleneck and Corrective action details. Weekly status reporting and scheduled meetings with program sponsor(s) Regularly updated project schedule, provided to project sponsors on a weekly basis
