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Rastek ID and Advantech Join Forces to Present a Cost-Effective AI-Powered Production Line Monitoring Solution

10/19/2021

Interview with Endro Sulistyo, key account manager of Advantech Indonesia

Based on the existing facilities and requirements of end customers, Rastek.ID and Advantech have collaborated to develop a cost-effective AI-powered solution for a large international electronic component and PCBA manufacturer in Indonesia.

According to Oxford Economics’ survey on 3,000 business executives around the world in 2020, AI (artificial intelligence) IoT and data analytics were found to be the top three prioritized technologies receiving investment in the past three years. However, Mr. Endro Sulistyo, key account manager of Advantech Indonesia, pointed out that due to the conservative mindset, most businesses in Indonesia are hesitant to adopt AI in their digital transformation journey. To date, only the transportation and manufacturing sectors are generally more open to AI-powered solutions. One project that Mr. Sulistyo worked on this year is an AI-powered video analytics inspection solution for a large international electronic component and PCBA manufacturer. The manufacturer did not have accurate records on when, why, and how many times production lines had stopped, and whether production operators had been following the SOP. The customer decided to improve the visibility of the day-to-day operations in order to not only identify bottlenecks, but also to perform further analysis to optimize production efficiency. 

Meeting the customer’s budget without compromising on AI video analytics

Initially, the customer had an evaluation from another system integrator who proposed a conventional video server combined with a high-end GPU to execute analytics. However, the total implementation cost far exceeded the budget, and the analytics process was more prolonged than anticipated. Through Intel®’s ecosystem, Rastek ID and Advantech collaborated to deliver a much more cost-effective AI-powered solution. Helping end customers in both public and private sectors, Rastek ID, who specializes in innovative AIoT and computer vision solutions, developed AI software based on the customer’s requirements and existing facilities. After several months of proof-of-concept (POC) testing, the AIR-300 Edge AI Inference System with a VEGA-340 AI acceleration card was chosen as the most suitable hardware platform for the custom AI software.

To meet the customer’s budget, Advantech’s AIR-300 was connected to the customer’s existing IP cameras, and new cameras were only installed at critical workstations, allowing the video streams to be analyzed via AI in real time. Analysis results, including production staff and machine status, were then sent to the customer’s back-end database, and administrators were notified of any abnormal events in real time, enabling them to take immediate action. Powered by an Intel® Xeon and Core i7 CPU, the AIR-300 offers high-performance real-time data processing power. The VEGA-340 Movidius™ Vision Processing Unit (VPU) card can be used to accelerate the AI and utilize the host CPU, thus providing scalable performance for edge applications where multiple cameras are required. The AIR-300 is preloaded with Advantech Edge AI Suite which integrates Intel® OpenVINO™ toolkit. The Intel® OpenVINO™ toolkit not only allowed Rastek ID to quickly develop the custom solution, but it also enabled inference time optimization for computer vision models.

Improving production efficiency and achieving ROI targets

The AI-powered production line monitoring solution has been running for six months. Video footage analysis time has since been decreased from one month to one or two days, and the human resource requirements have been reduced ten times. The customer was able to better understand the issues with staff behavior, such as loitering and working without protective gloves or goggles, as well as production issues, such as calibration scheduling and machine status. The analysis reports helped the customer discover issues, take corrective action, and improve production efficiency. The reduced human resource requirements also allowed the factory supervisors to better allocate their staff and manage capacity.

During the POC testing, Rastek ID and Advantech were able to modify the system and its features according to the requests of staff from different departments. “It was a long journey, but since this project is the first AI solution project in the manufacturing sector in Indonesia, we believe it will become the benchmark demonstration for other manufacturers.”, Mr. Sulistyo commented.  The customer was satisfied with the results and the targeted ROI should be achieved in less than one year. This has led the customer to use the same AI solution in other production sites. Rastek ID also reported that two other manufacturers are interested in POC testing with the same solution. Advantech Indonesia constantly shares the latest AI applications to local system integrator partners through webinars, and the company is very optimistic about the potential market growth of AI applications.

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