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We solve your most pressing manufacturing problem in max 2 weeks - with AI-powered Process Control.
Reducing waste, improving yield, ensuring quality, avoiding defects and disruptions - all of this can now be accomplished much faster and simpler than ever before. Vernaio's Process Booster is powered by causal AI, that brings statistical process control (SPC) to a whole new level, solving even the toughest challenges fast and 90% automated.
All of this you get in our Instant Solution Program, where we solve your manufacturing problem in only 2 weeks!
Check out these selected use cases where Process Booster has created significant value.
Industry: Pulp & paper | Process: Papermaking | Region - Germany
More Insights | Less failures
During the papermaking process, sheet breaks are a major disruption that occurs unexpectedly and requires extensive cleaning and rethreading before production can resume. To address this problem, Process Booster was provided with historical raw data from a paper production line. Using its causal AI, it performed a root cause analysis that uncovered multiple causes of sheet breaks, including some scenarios previously unidentified by process experts. Based on these insights, Process Booster was able to predict sheet breaks 60 minutes in advance, reducing their occurrence by up to 87% (50% on average). This significant reduction in downtime resulted in significant cost savings.
Industry:Steel | Process: Basic oxygen steelmaking | Region: Europe
More efficiency | Less slopping
In Basic Oxygen Steelmaking (BOS), a critical problem known as slopping occurs when foaming slag overflows, requiring containment and cleanup efforts. Unfortunately, with traditional methods, a slopping event can only be anticipated a few seconds before it actually occurs, leaving insufficient time to counteract it. To solve this problem, Process Booster processed raw historical data from a basic oxygen furnace. Using its causal AI, it performed a root cause analysis that identified all the key factors causing slopping. Using the insights and predictive models provided by Process Booster, the ability to proactively identify and address slopping events improved by 54%, with warnings provided 1 - 2 minutes (!) in advance, improving overall efficiency and safety.
Industry: Tobacco | Process: Cast leafs | Region - Germany
More efficiency | Less waste | More revenue
Adherence to strict quality standards is essential for the production of heated tobacco products. Deviations can lead to significant material waste, resulting in significant financial losses. Vernaio's Process Booster used historical raw data from a heated tobacco production line to perform a comprehensive root cause analysis. Using causal AI, Process Booster pinpointed all the key parameters affecting product quality and created a process control model for live operations. The model continuously predicts and monitors production quality and recommends corrective actions in case of deviations. As a result, Process Booster helped reduce waste by 75%, resulting in significant cost savings.
We solve your most pressing manufacturing problem in three simple steps.
Deliver your problem description
Provide historical time-series data, covering the problem area
Define parameters you can influence to change the system settings
We run your data in our AI engine for insights & new knowledge
We provide immediate results to speed-up time to value
We fine tune results based on your feedback
We tell you exactly what parameters are influencing your problems
We outline a holistic picture of the underlying root causes
We deliver specific AI countermeasures to solve your problem
We will share our intermediate results with you so you can directly validate our insights within your production processes.
Gain New Process Knowledge
We make our insights transparent and highly explainable (no black-box).
Get Actionable Results
We tell you which signals need to be changed and how to get the problem solved.
Increased Time to Value
We accelerated your learnings.
You have a specific problem to solve and can provide historical process data? Fantastic!
Apply for our Instant Solution Program, and we solve your problem in a focused two-week project.
Don't worry, this application is not binding. We will contact you directly for concrete next steps.
