EDGE FOR MANUFACTURING

Where the factory floor hits the fast lane

Explore edge use cases and architectures below that are transforming your industry.

Processes
Inspection
Monitoring
Maintenance
Workflows

Real-time process control

Equipment sensor data is analyzed to adjust process inefficiencies in real time.

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Closeup on lens connected to factory scanner.

Mechanical and electrical signals continuously streamed from high-precision IoT sensors, communicating process data, environmental data, and other data sources.

Finger pointing to graph on monitor screen.

Data sent to edge solution to perform advanced analytics and keep optimal values for process control variables.

Closeup of machines on a factory production line.

Operational system receives optimized process control variables, adjusting parameters in real time to maximize yield and product quality.

Portion of sensor data and results of analyses sent to public cloud to enable continuous learning of AI/ML algorithms.

Potential benefits

3-5%

yield improvement¹

3-5%

yield improvement¹

15-25%

product quality improvement¹

15-25%

product quality improvement¹

The solution stack for real‑time control

Lumen, supplemented by service and technology leaders like Cognizant and Lantech, provides the edge infrastructure you need to help improve production yield and quality. See how it all comes together in the full solution stack.

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Reference architecture for real‑time process control

Based on edge best practices in the manufacturing industry, Lumen maintains reference architecture outlining specific technologies to deliver your edge infrastructure needs and help you drive production to the edge of efficiency.

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Reference architecture for cloud computing in manufacturing.

¹McKinsey manufacturing expert interviews, January 2022.

How automated in-line optical inspection works

High-resolution photos captured during production are utilized by AI/ML to detect and flag defects.

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Cameras continuously take images of in-process inventory.

Looking down hallway lined on both sides with server stacks.

Images sent to edge servers for parametrization and AI/ML analysis to identify quality defects.

Results of analysis displayed on-site, where operator can remove defectives or stop production.

Quality data periodically transmitted to public cloud for model training

Potential benefits

5-10%

increase in throughput based on reduced cycle time¹

5-10%

increase in throughput based on reduced cycle time¹

20-30%

reduction of process rework¹

20-30%

reduction of process rework¹

The solution stack for optimized inspection

Lumen, supplemented by service and technology leaders like DXC and Cognex, provides the edge infrastructure you need to maximize throughput and minimize rework. See how it all comes together in the full solution stack.

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Reference architecture for in-line optical inspection

Based on edge best practices in the manufacturing industry, Lumen maintains reference architecture outlining specific technologies to deliver your edge infrastructure needs, reduce rework and help you drive production to the edge of quality.

VIEW ARCHITECTURE

¹McKinsey manufacturing expert interviews, January 2022.

How condition-based monitoring works

Equipment sensor data is analyzed in real time to monitor conditions and plan interventions remotely.

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Sensors (e.g., temperature, pressure, vibration) on equipment continuously stream measurement samples.

Sensor data analyzed in real time for anomalous conditions that could lead to equipment failure.

Person in viewing an industrial machine.

Equipment status continuously updated and made available to local and remote maintenance staff.

Person using tablet in front of industrial machine.

Conditions requiring intervention immediately detected and appropriate staff notified.

Potential benefits

75-90%

reduction in unplanned downtime¹

75-90%

reduction in unplanned downtime¹

60-80%

improvement in % of orders fulfilled¹

60-80%

improvement in % of orders fulfilled¹

The solution stack for maintaining ideal conditions

Lumen, supplemented by service and technology leaders like IBM and Nvidia, provides the edge infrastructure you need to minimize unplanned downtime and maximize fulfillment. See how it all comes together in the full solution stack.

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Reference architecture for condition-based monitoring

Based on edge best practices in the manufacturing industry, Lumen maintains reference architecture outlining specific technologies to deliver your edge infrastructure needs, keep orders on track and help you drive production to the edge of efficiency.

VIEW ARCHITECTURE

¹McKinsey manufacturing expert interviews, January 2022.

How predictive maintenance works

Sensor data is analyzed in the cloud to update maintenance schedules and prevent equipment failure.

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Plant equipment such as motors and pumps with external or OEM sensors (e.g., heat, vibration) transmit data to on-premises edge cloud solution.

Person holding phone receiver next to two computer terminals.

On-premises edge cloud solution collects, normalizes and analyzes data from connected assets.

Person on the factory floor next to monitory displaying graphs.

Factory employees are sent an updated maintenance schedule optimized to prevent machine failures.

Open server bay in a server room hallway.

Plant equipment data is periodically sent to the public cloud to help improve predictive ML models and analytics.

Potential benefits

10-30%

reduction in repair costs¹

10-30%

reduction in repair costs¹

8-10%

reduction in MRO parts kept in inventory¹

8-10%

reduction in MRO parts kept in inventory¹

The solution stack for proactive prevention

Lumen, supplemented by service and technology leaders like Accenture and Keyence, provides the edge infrastructure you need to minimize repair costs and parts kept in inventory. See how it all comes together in the full solution stack.

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Reference architecture for predictive maintenance

Based on edge best practices in the manufacturing industry, Lumen maintains reference architecture outlining specific technologies to deliver your edge infrastructure needs, maintain efficient equipment and help you drive production to the edge of performance.

VIEW ARCHITECTURE

¹McKinsey manufacturing expert interviews, January 2022.

Guided operator workflows

AR/VR allows an off-site expert operator to see what an on-site operator sees and manage accordingly.

VIEW USE CASE

Person with eye and ear protection toughing an industrial machine.

Handsfree headset captures and streams video showing what operator sees in real time.

Closeup of 3D-rendered image of machine part.

Headset view may be supplemented with text instructions, CAD images or IoT sensor data using AR technology.

Video streamed through edge infrastructure to remotely located equipment expert or senior operator.

Person wearing eye and ear protection touching industrial machine.

Remote expert provides instructions and support to on-site operator.

Potential benefits

60-80%

savings in annual operator FTE budget¹

60-80%

savings in annual operator FTE budget¹

50-80%

improvement in new worker onboarding time¹

50-80%

improvement in new worker onboarding time¹

The solution stack for enhanced operator control

Lumen, supplemented by service and technology leaders like IBM and HTC, provides the edge infrastructure you need to optimize your operator budget and minimize onboarding time. See how it all comes together in the full solution stack.

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Reference architecture for guided operator workflows

Based on edge best practices in the manufacturing industry, Lumen maintains reference architecture outlining specific technologies to deliver your edge infrastructure needs, maximize your operators’ skills and help you drive production to the edge of precision.

VIEW ARCHITECTURE

¹McKinsey manufacturing expert interviews, January 2022.

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*Offer limited to configurations, systems and server use requirements including maximum data volumes set out by Lumen and maximum service value of $10,000. Offer available to qualifying business customers for new service in eligible U.S. locations. Lumen may change, cancel, or substitute offers and services, or vary them by service area at its sole discretion without notice. Credit approval and deposit may be required. Offer may not be combined with other offers. Additional restrictions, terms and conditions apply.

**Offer limited to configurations, systems and server use requirements including maximum data volumes set out by Lumen and maximum service value of $10,000. Offer available to qualifying business customers for new service in Lumen’s EMEA operating region (as determined by Lumen). Lumen may change, cancel, or substitute offers and services, or vary them by service area at its sole discretion without notice. Credit approval and deposit may be required. Offer may not be combined with other offers. Additional restrictions, terms and conditions apply.