The customer is experiencing a challenge with their thermal barrier coatings on turbine blades. The coatings are requiring a high amount of rework due to issues such as poor adhesion and incomplete coverage. Non-conformance is often only detected at lab inspection several days after manufacturing, which is leading to delays and additional rework. Compounding the issue, the customer is unable to link machine settings to quality issues, which makes it difficult to identify the root cause of quality issues and take corrective action. Additionally, process inconsistencies are not traceable, which further intensifies the challenges.

With Insights Hub the customer integrates coating booth with the Insights Hub IoT platform, enabling real-time monitoring and data analysis to optimize production processes. Booth sensors continuously collect data and send it to the cloud, with transmission intervals up to every 1 second. With alarms configured to trigger based on production conditions, potential problems can be detected early and automatically initiate corrective actions or alert operators to intervene. Custom dashboards provide operators with real-time insight into production data, enabling informed decision making and improved overall productivity.