Our customer is a market leader in the production of heated tobacco products. They're currently in an exciting phase of expansion, driven by:

• High market demand for heated tobacco products
• Impressive double-digit Compound Annual Growth Rate (CAGR)
• The need to scale operations while maintaining product quality

This growth presents both opportunities and challenges, making it the perfect scenario for implementing our latest AI solutions.

Their heated tobacco production process faces several critical challenges:

1. Precision Requirements: Strict quality metrics must be maintained accurately throughout the coating and drying process with minimum deviation.
2. Multiple Critical Parameters: Key factors include moisture content, thickness, and grammage.
3. High Stakes: Any deviation will result in
   • Significant material waste
   • Increased energy consumption
   • Reduced final product yield

The combination of these factors creates an environment where traditional control methods struggle to keep up. See the screenshot below for the high deviations of one KPI.

To address these complex challenges, we implemented a comprehensive AI-powered solution:

1. Unified Quality Metric:
   • Developed a comprehensive target KPI combining deviations of moisture and grammage profiles.
   • Set precise limits on this target KPI to ensure both deviations remain within allowed ranges.
2. Data Integration:
   • Fed raw historical process data into aivis®, our causal AI engine powering the Process Booster.
3. AI-Powered Analysis:
   • Conducted a thorough root cause analysis to identify all key parameters affecting the target KPI.
   • Uncovered hidden patterns and correlations in the production process.
4. Predictive Modeling:
   • Created a causal AI-driven process control model for the KPI.
   • This model predicts KPI behavior and facilitates proactive corrective action.
5. Real-Time Alerts and Adjustments:
   • Implemented a system that warns operators whenever the KPI is at risk of falling outside its defined corridor.
   • Provides real-time setpoint adjustment recommendations to machine operators
6. Live Root Cause Analysis:
   • The model offers real-time root causes insights by showing all factors currently responsible for any deviation.
   • This feature enhances understanding of the process and supports continuous improvement.

The implementation of our AI-powered process control solution delivered remarkable results:

1. Predictive Accuracy:
   • The aivis® model predicted the target KPI with an outstanding accuracy of R² ~91%.
   • This high level of accuracy ensures reliable insights and recommendations.
2. Waste Reduction:
   • Projecting a 75% reduction in waste, from 4% to just 1%.
   • This improvement translates directly into substantial cost savings and improved resource efficiency.
3. Enhanced Process Control:
   • Operators gained the ability to make timely, informed decisions based on AI recommendations.
   • This proactive approach prevented quality issues before they could impact production.
4. Scalability and Consistency:
   • The AI solution proved capable of maintaining high-quality standards even as production scaled up.
   • This consistency is crucial for meeting growing market demand without compromising product quality.
5. Long-term Benefits:
   • The continuous learning nature of the AI system means it will keep improving over time, adapting to process changes and new challenges.
   • This ensures the solution remains effective and relevant as the production environment evolves.

See the screenshot below to see our model performance

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The implementation of AI-powered process control in heated tobacco production has proven to be a game-changer. By dramatically reducing waste, improving prediction accuracy, and providing real-time insights, this solution addresses the core challenges faced by manufacturers in this rapidly growing industry.

For companies looking to optimize their heated tobacco production processes, this case study demonstrates the tangible benefits of embracing AI technology. The potential for significant cost savings, improved product quality, and enhanced scalability makes this an attractive solution for both current market leaders and emerging players in the heated tobacco market.