Formula 1™ used to be a head-to-head battle between the world’s most skilled drivers and the sport’s top car manufacturers. That’s still true but, more than ever, races can be won or lost by decisions made off the track as well as on. In the high-pressure F1™ paddocks engineers, mechanics and, crucially, data scientists and strategists analyse vast amounts of highly technical information transmitted in real-time from more than 300 sensors on their team’s cars. These measure everything from tyre degradation to brake drum temperatures, wind speed to fuel flow. Insights are shared with the drivers and support team to allow them to make informed split-second decisions.

Take the Aramco United States Grand Prix 2021 for example. Max Verstappen (driving for Red Bull Racing-Honda) led the drivers’ championship from Lewis Hamilton (Mercedes) by six points. Verstappen had qualified on pole with Hamilton second on the grid. Within seconds Hamilton had grabbed the lead, and Verstappen was forced to play catch-up.

That was, until the Red Bull team made the bold tactical decision to use the ‘undercut’ technique and pit Verstappen early. The fresh set of tyres gave him an instant advantage over his rival and, as Hamilton’s tyres began to degrade, Verstappen was able to record faster lap times and regain his lead. By making Mercedes react rather than dictate the strategy Red Bull had seized control. It was a risk, no doubt about it. Verstappen had the faster car, but his second set of tyres would degrade sooner than Hamilton’s.

In the final lap there was just one second between the two cars. That was enough for Verstappen to overtake a backmarker, entitling him to use his Drag Reduction System (DRS), seal the win and take the Championship.

The devil is in the detail

What can manufacturers learn from this example? If knowledge is power, data-informed knowledge is omnipotent.

Let’s say you’re a food producer and demand for your product is growing. Then you discover, as a large order is ready to be shipped, that your packaging has a consistent fault. It may be serious enough for you to stop the assembly line or relatively small but nonetheless a poor reflection on your brand. Either way, your profitability, margins and reputation will be impacted. Now imagine you had smart sensors gathering essential data from limited access-points, in real time, meaning you were able to identify and isolate issues at pace, accelerate resolution and put predictive maintenance in place to flag potential issues before they become a problem.

Or maybe you’re missing your productivity KPIs but your complex technology is getting in the way of improving efficiency. You may already have theories and potential solutions, as well as a certain amount of existing data, but are concerned about the cost of disrupting your day-to-day activity to test different models. An alternative might be to create a digital twin (a virtual prototype) of your existing set up, simulate different scenarios and gather real-time data to help your decision making.

In a world of ever-increasing complexity and unrelenting demands for greater performance, manufacturers need to make informed, iterative changes at pace. Just like they did on that Championship defining day at the Circuit of the Americas.

Race-derived tools, technologies and techniques

PurpleSector is an engineering-led, data-driven consultancy that works shoulder to shoulder with manufacturing clients to find solutions for complex, high stakes operational challenges.

We use cutting-edge F1™-derived tools and technology to get to the root of issues at pace. We help you cut through the white noise of data by gathering and analysing exactly the data you need to accelerate improvements and uncover opportunities. At pace.

We know that every millisecond of downtime counts. Every detail matters. In the same way that pit crews focus on marginal gains, we know even the smallest improvements can make a significant difference.

We’re currently working with the team at Mondelez International where we’re using our Formula 1™-derived simulation techniques, machine vision tools and data analytics algorithms to fine tune the wrapping of the ever-popular Creme Egg increasing perfection and reducing rejection.

We encourage our clients to embrace a culture of continuous improvement, where every employee is empowered to identify and implement small changes that can lead to big results. If that sounds relevant or interesting to you, come and visit our stand or get in touch before the event. Hope to see you soon!