High Performance Alloys

Client

US’s largest aerospace manufacturer operates 150 factories producing raw materials through finished parts

Problem

A complex three month production process from powder to billet spanning four factories has suffered from persistent, multi-year quality problems.

Solution

OMAHA is used to investigate underlying causes and improve yields. Data is sourced from multiple SQL databases, historians and the enterprise data lake, as well as high-speed videos and varmetrics in a proprietary file format stored on a 300 TB
on-premises NAS. Multiple OMAHA instances are linked, spanning a complex network topology across 3 DMZs.

Outcome

Diagnostic and exploratory dashboards for process engineers and metallurgists complement Jupyter notebook interface for power users conducting ad‑hoc analyses. Decision support system enables early detection of potential defects and downstream sales routing.

ROI

First draft implementation completed in under two weeks yielded $650K annual savings.