Industries
AI for process manufacturing
Trace every tonne from the weighbridge to the finished output, so what enters the gate reconciles with what leaves the line.
How does MarsLab build AI for process manufacturing?
Two engagements built around live floor data instead of paper trails. At Sanjeevani Group's sugar, ethanol, power and biogas complex, MarsLab lifted sugar recovery to 9.5%, cut downtime and exposed a 300 crore audit gap by rebuilding the plant on live data. At a biscuit manufacturing plant, MarsLab digitised 300 kg of daily output to the item, closing losses across intake, production and packaging with a full mass balance.
What process manufacturing digitisation connects
Manufacturing losses are often present in the operation long before they appear in a report. Process data can sit in registers, production stoppages can be recorded without a cause, and inventory can be issued without a record of the machine or section that consumed it. The result is a plant where material movement, downtime, quality and finance are hard to reconcile in time to change the outcome.
MarsLab connects the floor and the operating system around the plant. That can include sensor-fed production data, PLC and SCADA integration, mobile capture where a human reading is required, downtime logging, procurement controls, inventory allocation and an ERP that shares one source of truth with stores, process and accounts.
The relevant control depends on the plant. At Sanjeevani Group, live pan-station parameters, vendor workflows and ERP reconciliation addressed recovery, downtime and audit risk across a sugar complex. At a biscuit plant, item-to-machine allocation, mass reconciliation and packaging analysis made material and production losses visible and costed.
- /Live production and process readings instead of delayed paper reporting
- /Downtime recorded with cause and duration, so repeat failures become a dataset
- /Input, output, rework and consumables reconciled against physical plant activity
- /Procurement, stores, process and accounts connected to the same operational trail
Solutions and use cases
Relevant services
Engagements in Manufacturing & Industrials
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