IntraStage has been developing analytics software for manufacturing for over two decades. Our solutions play an integral role in the product lifecycle and operations for the most demanding quality requirements.
Anticipating IC Performance
Maintain tight performance tolerances of RF semisonductor design. Very large datasets meant that, in some cases, it took over two days just to aggregate data and forming it to be ready for analysis.
Manufacturing and NPI data needed to be aggregated to allow limit tuning and measurement variance.
LEONARDO needed to identify and minimize manufacturing/repair touch time as well as the ability to investigate yield and performance issues at multiple sites with Secure and Secret deployments.
They required the ability to analyze disparate data from complex test systems and normalize analysis data from ATML, NI TestStand, LabVIEW TDMS, PDF and text, CSV and Excel formats.
Highly complex products with tight safety and reliability metrics. Need to analyze production data to quickly identify issues affecting yield and performance. Data aggregation from AOI,AXI,ICT,FCT, ESS, Failures, Rework and ATP performance test.
Apply Statistical Process Control ( SPC) across a wide number of process variables such as CpK.
“IntraStage core technologies has enabled the visibility needed to achieve a 90% reduction of our yield issues. This helped ultimately reduce our Cost of Goods Sold by £ 500,000 / year via achieving target improvements in Rolled Throughput Yield.”
General Atomics needed to analyze gigabytes of test data from ATEs producing LabVIEW and TestStand data outputs on the manufacturing floor to identify issues that affect manufacturing efficiency and product quality.
They also wanted to be able to digitize paper-based manufacturing data capture to facilitate data analysis and improve process integrity.
IntraStage was also tasked with enabling the processing of data from multiple manufacturing lines and systems.
Lack of visibility into failure reasons and yield issues. Lack of tracking process anomalies which impact the overall manufacturing throughput.
Lack of characterization on performance issues.
No way to be proactive on line-stopping issues and problems. Ability to monitor critical KPI’s in real-time with Alerting and enterprise level visibility.
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.
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 ).
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 Enterprise is an integrated suite of products that optimizes product performance, quality, and efficiency for electronics manufacturers by automating, digitizing, and analyzing lifecycle data and KPIs from across the enterprise.