The Path to Digital Transformation: Leveraging Data for Industrial Inspection

Introduction 

In contemporary industrial landscapes, inspection and process monitoring are indispensable. These processes underpin both efficiency and safety throughout the product lifecycle. However, for many manufacturers and asset owners, these critical operations are often perceived merely as necessary expenditures rather than opportunities for value creation. 

In an era of abundant information, we are increasingly faced with overwhelming quantities of sensor data generated from every facet of design, production, and inspection. This data surplus, rather than presenting an insurmountable challenge, offers an unparalleled opportunity to transform inspection processes into valuable assets that yield compounded benefits for customers. 

The Challenge of Data Integration 

Despite the potential inherent in sensor and inspection data, its sheer volume and complexity often hinder effective value extraction. Frequently, the data collected falls into one or more problematic categories: 

• Fragmented, siloed, and overlooked information. 

• Isolated inspection and monitoring tasks lacking supplier integration. 

• Multiple sensor inputs producing disconnected results. 

• Limited process feedback devoid of actionable insights. 

Addressing these issues is crucial. By doing so, the very concept of inspection shifts from being a sunk cost to a source of valuable insights. Inspections not only identify defects but, more critically, provide the information needed to prevent them. 

The AAA Philosophy: Acquire, Analyze, Act 

It is widely acknowledged that raw data alone holds little value. True value emerges when data is comprehensively acquired, accurately linked to relevant information, and thoroughly analyzed to extract meaningful insights. This process culminates in actionable intelligence that can be implemented in a timely manner. At Waygate Technologies, we refer to this approach as the AAA philosophy: Acquire, Analyze, Act. This methodology enables data to be processed from its source, transferred to the cloud, and then re-applied to generate multi-generational value for our customers. 

ACQUIRE: From Asset to Cloud 

The acquisition phase begins with connecting all inspection and sensor devices. This integration allows for the seamless collection of necessary data and paves the way for numerous enhancements, including software upgrades, user training, and remote expert assistance—all accessible directly from the device. 

ANALYZE: Leveraging Data in the Cloud 

The analysis phase involves comprehensive contextual data management through a unified interface. Such management allows data to be harnessed for generating insights. The ubiquity of data naturally facilitates advanced analytics, enabling the use of fleet analytics, predictive maintenance, automatic defect recognition, and data fusion. These tools deliver actionable intelligence to customers. 

For deeper insights, inspection and sensing processes can be optimized through Artificial Intelligence (AI) and Machine Learning (ML), which enrich data outputs. Additionally, intelligent combinations of multiple inspections—either on the same component or across different parts—can be realized. This convergence of advanced technology ensures that the data derived from inspections is both enriched and robust, delivering significant returns to customers. 

ACT: From Cloud to Asset 

The ultimate objective of this process is to elevate industrial inspection and sensing from a routine quality assurance measure to a catalyst for innovation in product design and operational efficiency. Implementing the ACQUIRE and ANALYZE strategies drives innovation across the entire lifecycle of a part, from initial design to final deployment and beyond. 

When properly applied, the AAA philosophy empowers customers to achieve continuous improvements across generations of products. This is facilitated by virtual feedback loops that utilize insights from inspection and sensor data. Moreover, the integration of inspection solutions and sensors throughout the customer’s value chain enables feedback across all areas of design, manufacturing, and maintenance processes. From CAD models to design software, this integration drives innovation throughout the entire asset lifecycle.