Your production line: AI‑Driven Scrap Reduction

Manufacturers lose significant value to scrap, rework, and product rejections. In one recent production environment, material-related scrap and rework reached approximately $2.9M USD in the last 12 months—underscoring the need for deeper root-cause insight, proactive risk management, and continuous improvement powered by data and AI. This offering brings together Microsoft Fabric, Power BI, and AI Agents to unify scattered data, reveal drivers of defects, predict risk at the batch/order level, and recommend actions that reduce waste while improving throughput and quality.

Solution Overview We deliver a production-grade MVP built on Microsoft Fabric and Power BI that centralizes your quality and production data, provides granular analytics, and deploys explainable machine learning with a generative AI assistant utilizing data agents for root-cause Q&A.

• Data platform: Fabric OneLake with Lakehouse/Warehouse and medallion architecture (bronze–silver–gold) for governed, traceable data pipelines and a shared semantic model
• Analytics: Power BI dashboards replace limited views and add batch-level granularity for materials, components, suppliers, operators, lines, and sites. Fabric Data Agents enables natural-language Q&A on defects, trends, and drivers
• Predictive ML: A batch-level defect risk model optimized to detect defects risks early; daily refresh and MLOps monitoring/retraining; SHAP values for transparent explanations
• Generative AI: A domain-aware agent that answers “why” questions, reconciles station error-code mismatches, and explores scenario tables (grid-sweep) from the ML model to suggest risk-reducing actions
• Governance and security: End-to-end lineage, role-based access via Azure AD groups, MFA, least privilege, Key Vault for secrets, managed identities, logging/monitoring, and private endpoints to Fabric and Azure components

Key Features and Capabilities

• Unified, governed data integration
• Granular scrap analytics & Interactive dashboards
• Predictive risk scoring and planning support
• Generative AI assistant for root-cause and actions
• Enterprise-grade governance and security

Key Benefits

• Reduced scrap and rework costs: Direct impact on material and labor waste by targeting the drivers of defects
• Faster root-cause discovery and action: Move from manual, fragmented investigation to governed data, explainable ML, and generative Q&A that shorten time-to-insight and time-to-remediation
• Improved production planning and quality: Predictive risk scoring at batch/order level, scenario testing, and prioritized actions to reduce defects before they occur
• End-to-end traceability and trust: Medallion architecture, lineage, and explainability establish a defensible foundation for continuous improvement and audits
• Secure, scalable Microsoft architecture: Built on Microsoft Fabric and Power BI, aligned with Azure security best practices and ready to onboard additional sources (e.g., Dynamics 365 FinOps)

Are you ready…. …to cut scrap, boost quality, and accelerate continuous improvement with AI? We are with you all the way!

Request a discovery workshop to map your data sources and target outcomes.

About Accigo We are your partner with deep expertise in Data & AI, helping organizations simplify technology, modernize processes, and build intelligent applications on Azure and Power Platform. Our combination of strategy, facilitation, design thinking, and Azure engineering ensures practical results and a clear path from ideas to agent-driven processes.