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Manufacturing

Manufacturing analytics, and AI agents that ask a person before they act.

When the plant and finance bring different numbers to Monday's meeting and your engineers are busy, ours join your team, wire the ERP, the scale house, the historian and the lab into numbers both sides trust, and build agents on them that send every exception to a person.

  • Cyclic Materials
  • Funko
  • SRS Distribution
  • MATT Construction
  • DeTect
  • Databricks partner
  • Microsoft Solutions Partner

Video · 1:18

How Databricks gives a plant one set of numbers from five systems

Chapters and the full transcript

The problems

What we're brought in for

  • Two numbers for one metric

    The plant and finance bring different throughput figures to the same meeting, and each is right by its own definition.

  • Answers spread across six systems

    Ramp-up, yield and receiving each need a different export, and someone matches supplier names by hand.

  • Parts nobody can find

    Engineers search a catalogue of many thousands of parts, and when search fails they pick up the phone.

  • Certificates lost in email

    Quality documents travel as attachments, and a missing one can send a good part to scrap.

What we build

What we build in manufacturing

Data and AI on Databricks6

  • A manufacturer's new plant

    Plant leadership dashboards

    Nine dashboards, from ramp-up against nameplate to a supplier scorecard, built and tested on sample data before go-live.

    • One definition per metric in gold
    • A ten-week plan to go-live
    DatabricksLakeflowAI/BI dashboards
  • A manufacturer's new plant

    ERP data beside plant data

    Business Central lands next to the historian, the lab and the scale house, and silver reconciles units and supplier names once.

    • Supplier names reconciled in silver
    • Reports read gold, never a copy of a measure
    Business CentralUnity CatalogAI/BI dashboards
  • A manufacturer's new plant

    Receipts matched to scale tickets

    Each Business Central receipt is matched to its scale ticket, and the ones that differ are listed for someone to check.

    • Unmatched receipts listed for review
    • The same tables as the dashboards
    Business CentralDelta tables
  • A manufacturer's new plant

    Genie on the gold tables

    Plain-English questions answered from the same gold tables the dashboards read, each answer with its chart and the SQL behind it.

    • Each answer shows its SQL
    • The question and the chart agree
    GenieUnity Catalog
  • How we'd build it

    Genie answers you can measure

    We'd write benchmark questions with known answers and run them after every change, so a renamed column shows up as a drop in accuracy.

    • Accuracy tracked over time
    • Definitions hardened under the Genie space
    GenieAI/BI
  • How we'd build it

    Agents for copy-and-paste work

    Where someone still copies numbers between systems, we'd add an agent and send every exception to a person to approve.

    • A person approves each exception
    • Every action recorded
    Databricks AppsUnity Catalog

ERP3

  • Built for Funko

    Funko's warehouse on Business Central

    When Funko consolidated distribution into one Arizona warehouse, our engineers extended the system it already had, on site.

    • 2× operational efficiency
    • No start-over rebuild
    Business CentralAzure Data Factory
  • Built for AZP Multifamily

    Epicor Prophet 21 and a Snowflake warehouse

    We tuned AZP Multifamily's Epicor Prophet 21 and built a Snowflake warehouse on Azure with Power BI dashboards for each team.

    • Sales, marketing and ERP data together
    • Buy-again suggestions for each property
    Epicor Prophet 21SnowflakePower BI
  • Our Insight Works partnership

    Business Central and Insight Works

    Implementation and on-site support for the warehouse and production transactions that run through Business Central.

    • Engineers at your facility when it helps
    • Warehouse and shop floor on one ERP
    Business CentralWarehouse InsightShop Floor Insight

Software2

  • Built for NMBTC

    Parts catalogue search

    NMBTC's product database, search filters and navigation, rebuilt inside the WordPress site it wanted to keep.

    • 145% more inbound B2B leads in the first month
    • Kept the WordPress site it had
    WordPressUI/UX
  • Built for SmartCert

    Traceable quality certificates

    A QR code on each package opens that shipment's certificates, and links to Epicor Prophet 21 and Business Central stop the retyping.

    • No certificate lost since launch
    • Nobody retypes a certificate
    Azure.NET CoreReact

Reference architecture

How the data fits together in manufacturing

The ERP and the plant systems land side by side, get reconciled once, and every chart, Genie answer and agent reads the result.

1 · Business Central

2 · Databricks lakehouse, Unity Catalog
silver reconciles units and supplier names

1 · Scale house and lab

1 · Line historian
and market prices

3 · Gold
one definition per metric

4 · Power BI or AI/BI dashboards

4 · Genie space

4 · Agents, with a person
approving each exception

The ERP and the plant systems land side by side, get reconciled once in silver, and every dashboard, Genie answer and agent reads one definition per metric.
  1. Step 1: Read from levels 3 and 4

    Business Central, the scale house, the line historian, the lab and market prices are read where they already live, and the control systems are left alone.

  2. Step 2: Reconcile once in silver

    Units, supplier names and receipt numbers are matched in one place, instead of in every spreadsheet that needs them.

  3. Step 3: One definition per metric in gold

    Utilisation, backlog in days, yield by supplier and downtime by cause each get one agreed formula.

  4. Step 4: Dashboards, Genie and agents

    Power BI or AI/BI dashboards, a Genie space and any agent all read gold, so the plant and finance see the same number.

Proof

Work we've shipped in manufacturing

Compliance and governance

The standard and the governance we build in

  • ISA-95 levels 3 and 4

    The standard sets the interface between manufacturing operations and business systems, which is where we read and integrate.

    Source: ISA on ISA-95

  • Lineage to the column

    Unity Catalog records which tables and columns a number came from, so an auditor's question about it becomes a query.

    Source: Databricks, data lineage

  • Access by plant and role

    Row filters and column masks decide which plant, supplier or team sees which rows, on the same tables for everyone.

    Source: Databricks, row filters and column masks

The longer version is under In depth.

How we engage

Ways to start

  • Two weeks, fixed fee

    Databricks Health Check

    Reads cost, job reliability and Unity Catalog coverage on the platform you already run, and ends in a ranked scorecard.

  • Six weeks, after discovery

    Lakehouse Launchpad

    A governed lakehouse from a standing start, with Unity Catalog in place before the first pipeline and dashboards for the people who asked for them.

  • Two to four weeks

    Genie Accuracy

    Hardens the definitions under a Genie space and builds the benchmark questions that show whether its answers are holding.

  • Two weeks, fixed fee

    AI Readiness Assessment

    Names the use case worth building first, the data and permissions it needs, and what it would cost to run for a month.

  • For the length of the engagement

    Forward-deployed engineers

    Senior engineers in your workspace and your repository, as a team with a lead or as individuals under yours.

In depth

Manufacturing in depth, with sources

A plant keeps its answers in six places. The ERP knows what was ordered and received, the scale house knows what actually came through the gate, the line historian knows how hard the equipment ran, and the lab knows what the material was worth.

We join those once on Databricks, governed by Unity Catalog, with one definition per metric so the ramp-up chart and the supplier scorecard stop disagreeing. Business Central stays the system of record, and the engineers who implement it build the reporting too, with no handoff to a separate BI team, so the model knows what a posting group means.

Power BI or AI/BI dashboards and a Genie space sit on top, and around it all are the systems manufacturers run every day: catalogue search for engineers, procurement, traceable quality documents and order management.

Dashboards for a plant, not for a slide

The reports that get opened on a Monday answer operational questions. How far is the line from nameplate this week? How many days of work are sitting in the yard at the current rate? Which supplier's material is getting worse, and is it costing yield?

Which receipts don't match their scale tickets? The plant leadership study at /case-studies/plant-leadership-reporting-databricks carries nine of them, from ramp-up and downtime by cause to a supplier scorecard and a mass balance that follows every tonne, and the screenshots are on that page.

ERP data next to plant data

Power BI on Business Central alone is enough when the ERP is the only source that matters. It stops being enough when the question needs the historian, the lab or the scale house as well, because those were never going to live in the ERP.

That's when a lakehouse earns its place: each source lands with lineage, silver reconciles units and supplier names, and gold holds one definition per metric for every report and every Genie question to read. How we decide between the two is at /expertise/erp-reporting.

AI on plant data

Most AI for manufacturing starts with a question someone asks every week and waits days to answer. The plant leadership study at /case-studies/plant-leadership-reporting-databricks, built and tested on sample data before go-live, puts a Genie space on the same gold tables as the dashboards, so a plain-English question and the chart give the same answer.

We'd add an agent next where a person still copies numbers between systems, such as matching receipts to scale tickets, with every exception routed to someone to approve.

Catalogues, procurement and quality

Findability is its own job. An engineer searching a catalogue of hundreds of thousands of parts either finds the right one in seconds or calls someone, and every downstream process inherits that.

NMBT at /case-studies/nmbt was research into how engineers search an electro-magnetic parts catalogue. SmartCert at /case-studies/smart-cert replaced emailed certificates with a traceable exchange between manufacturers, distributors and their customers.

FAQ

Manufacturing: questions we get asked

How do you keep an AI agent on plant data under control?

By designing the controls in before the agent is built. The agent reads only the governed tables it is granted in Unity Catalog, every action it proposes, such as matching a receipt to a scale ticket or flagging a supplier lot, is checked against policy before anything changes, and exceptions go to a named person to approve.

Each decision is recorded, so quality and finance can trace it later, and the same checks run in testing as in production. The Field Guide's chapter on governed actions walks through this kind of check, and our AI agent services build it.

What should a manufacturing dashboard show?

Whatever leadership argues about on a Monday, measured the same way every week. For a plant in ramp-up that's usually utilisation against nameplate, backlog in days at the current rate, downtime by cause, yield by supplier and receiving exceptions.

Each one needs a single agreed definition before it gets a chart, which is most of the work. The plant leadership study at /case-studies/plant-leadership-reporting-databricks shows nine of them.

Is Power BI on our ERP enough, or do we need Databricks?

If every number you need is in Business Central, Power BI on the ERP is enough and cheaper. Once a question needs the line historian, the lab, the scale house or market prices, a lakehouse is how those join the ERP under one definition.

Both readings of the same metric then come from the gold layer rather than from two copies of a measure. The trade-off is laid out at /expertise/erp-reporting.

How much of this is manufacturing-specific?

Less than you'd expect. The NMBT work at /case-studies/nmbt was UX research into how engineers search an enormous electro-magnetic parts catalogue, and findability under that kind of volume behaves the same way in distribution, retail and lending. The domain shapes the vocabulary and the compliance surface; the engineering underneath transfers.

We need traceability for audits. Where does that come from?

From treating lineage as a product feature rather than a logging setting. SmartCert at /case-studies/smart-cert replaced emailed certificate attachments with a traceable exchange between manufacturers, distributors and their customers. On Databricks, Unity Catalog gives you the substrate and someone still has to ship the workflow people will use.

Do you build plant-floor or control systems?

We read from them and don't build them. A line historian, a downtime log or a lab system is a source we land in the lakehouse and join with the ERP. Industrial control itself, the PLCs and SCADA that run the equipment, is a separate discipline, and the people who build it should keep owning it.

How long does a plant reporting platform take to build?

The plant leadership study at /case-studies/plant-leadership-reporting-databricks has a ten-week plan to go-live, and the build behind it is 12 bronze, 15 silver and 10 gold tables from seven sources.

Week one is read access to Business Central and exports from the plant systems, because the dashboards were built and tested on sample data first. Starting from nothing, the six-week Lakehouse Launchpad at /databricks/launchpad stands the governed foundation up.

Can you support Business Central and Insight Works on the shop floor?

Yes. We're an Insight Works partner, and we implement Warehouse Insight, Shop Floor Insight, License Plating and Dynamic Ship on Business Central and support the warehouse and production transactions that run through them, on site where that helps. The detail is at /expertise/business-central-insight-works.

Talk to someone who has built this.

A technical conversation with a senior engineer who has shipped in manufacturing, about what you're trying to build.