Calix

CASE STUDY

Manufacturing and Returned Materials Analysis and Process on high-volume communication devices.

Challenge:

As a high-volume manufacturer with a dedication to higher quality and lower customer returns, Calix needed a way to track and control the RMA process.

RMA data for each customer was tied directly to customer satisfaction and Calix profitability.

Needed to replace two existing, incompletely integrated RMA/FRACAS commercial, off the shelf software system and processes in a very tight (less than one month) timeframe.

Solution:

Staged approach leveraging BlackBelt’s off the shelf data model and ETL capabilities, enabling a 30 day turnaround on all RMA data import and reporting needs.

Rapid deployment of Return Analysis and IntraStage BlackBelt products to capture and track and control incoming new RMA events.

Custom report training to develop both executive level analytics and drill-down reports for both manufacturing and Return Analysis insight.

Benefits:

Successful and rapid deployment, validation, and use of RA software and BlackBelt Manufacturing system.

Deeper insights into correlation of manufacturing performance and RMA results.

Previously un-seen analytics into RMA details, providing new insight into business-critical processes and results.

“The software is very easy to use and we were able to train several of our internal customers to use IntraStage to pull the reports they needed without our help, which saves them a lot of time.”

– Senior Quality Engineer

CASE STUDY:

Challenge:

Multiple product lines with data from across the product lifecycle, including supplier subcomponents, contract-manufactured lower-level assemblies (LLAs), and higher-level assemblies (HLAs).

Need for correlation and tracking of performance, rework and reassembly of LLAs into and with HLAs with full product genealogy.

Need to integrate Manufacturing data with enterprise systems (Flexflow-MES, Team Center – PLM, Agile PLM, Spider- QMS, BOM and Oracle – ERP/AVL ).

“IntraStage is about realizing our vision of the factory of the future.”

– Director of Engineering

CASE STUDY:

Challenge:

Yield issues with a lack of visibility into the factors contributing to yield variations.

Need to aggregate data from multiple ATE systems and paper-based processes for compliance and performance insight.

Test station verification/validation and efficiency issues.

Retest issues without visibility into the cause of retest.

Need for ITAR-compliant data security.

“BlackBelt not only provides instant insights into our complex product performance, but also has streamlined our manual workflows with Paperless Manufacturing. This has achieved a new level of visibility into our supply chain and, with a hybrid cloud solution, provides transparency to our customers beyond compliance. This is saving us hundreds of man hours and servicing our customers better.”

– Senior Test Engineer

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