Executive Summary
The client, one of India’s leading private sector enterprises with a diversified presence across FMCG, hotels, packaging, paperboards & specialty papers, and agri-business, sought to enhance manufacturing quality through data-driven insights. Using Golden Batch Analytics, the initiative focused on optimizing key SMD quality parameters with advanced machine learning models, enabling predictive control, improved product consistency, and greater manufacturing efficiency.
Business Challenge
- The client wanted to implement Golden Batch Analytics to optimize production parameters, enhance product quality, and ensure consistency
- This involved modeling and controlling SMD quality parameters such as PDO Mean, PDO SD, QR SMD Mean, Firmness Mean, Firmness SD, Moisture Mean, and Circumference Mean/SD
- The existing manual process relied heavily on operator judgment and lacked data-driven scientific intelligence
- An earlier PPQRS Ex-Stem Cutter Moisture Mean Modeling and Optimization initiative had already been successfully completed and implemented
Business Challenge
- The client wanted to implement Golden Batch Analytics to optimize production parameters, enhance product quality, and ensure consistency
- This involved modeling and controlling SMD quality parameters such as PDO Mean, PDO SD, QR SMD Mean, Firmness Mean, Firmness SD, Moisture Mean, and Circumference Mean/SD
- The existing manual process relied heavily on operator judgment and lacked data-driven scientific intelligence
- An earlier PPQRS Ex-Stem Cutter Moisture Mean Modeling and Optimization initiative had already been successfully completed and implemented
Our Solution
- SMD Quality Parameters: PDO Mean, PDO SD, QR SMD Mean, Firmness Mean, Firmness SD, Moisture Mean, Circumference Mean, Circumference SD
- Raw dataset quality checks and exploratory analysis
- Univariate, Bivariate, and Multivariate distribution analysis
- Feature Engineering
- Development Regression and Optimization models
- Comprehensive reporting of analysis, model outputs, and findings
- Offline evaluation and testing of models and optimizer
Key Results and Benefits
- Extensive variable distribution analysis, including brand and blend influence, univariate and multivariate distributions (Correlation and PCA)
- Developed a range of machine learning models: Linear Regression, Generalized Additive Model, Random Forest, Gradient Boosting, ANN, Stacked Ensemblers
- Achieved >90% Model Adequacy and >98% Model Accuracy (<2% MAPE)
- Utilized stochastic optimization with Genetic Algorithm for faster convergence in control band recommendations
- Achieved >95% accuracy (Hit Rate) in recommended controllable variable limits, resulting in Golden Batch production for PPQRS Ex-Stem Cutter Moisture Mean post implementation
About ITC Infotech
ITC Infotech is a leading global technology services and solutions provider, led by Business and Technology Consulting. ITC Infotech provides business-friendly solutions to help clients succeed and be future-ready, by seamlessly bringing together digital expertise, strong industry specific alliances and the unique ability to leverage deep domain expertise from ITC Group businesses. ITC Infotech is a wholly owned subsidiary of ITC Ltd., a 100-plus-year-old diversified conglomerate with businesses spanning Hotels, Consumer Goods, Paperboards & Packaging, Agri Business, and Information Technology. ITC Ltd. has been in the hospitality business for over 4 decades. It has over 100 properties across 70+ destinations. The hospitality practice at ITC Infotech is 800+ people strong and most have experience in the hospitality domain leading to a high-quality IT service experience for its hospitality customers.
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