LEONARDO

CASE STUDY

Leonardo (formerly Selex Electronics Systems/Selex Galileo)

Advanced engineering company, committed to delivering winning, cost-effective solutions in the aerospace and defense sectors.

Challenge:

LEONARD needed to identify and minimize manufacturing/repair touch time and 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 various Text, CSV and Excel formats.

Solution:

Aggregation of manufacturing and field/return data from Integration, ESS Thermal, ESS Vibration, Pre-ATP, ATP.

Identify trends such as: measurement variation between test stations, test software impact on performance, and operator impact on performance and yield.

Continuously gathering of test data fin any format, NI TestStand, LabVIEW TDMS, PDF, and multiple variants of .txt, CSV, and Excel formats with hundreds of metadata points for performance characterization.

Benefits:

Minimized manufacturing/repair touch time
Faster production throughput
Reduction in Defect Per Unit (DPU) for high value assemblies
Measure and track Throughput Yield
Single source of truth for as-built performance
Multi-site cross functional collaboration
Reduction in high value resource demand

“Within two months of implementation of IntraStage, we improved our DPU rate. We generate a lot of test data and the manual effort to collect it, aggregate it, and analyze it through ad-hoc software solutions was very time consuming.”

– Senior Engineer, Captor-E Radar System

CASE STUDY:

Challenge:

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.”

– Engineering Manager-Engine Controls

CASE STUDY:

Challenge:

Disparate datasets created by different engineers, groups, or projects represent a challenge when trying to analyze performance over time. Previously, days of work was required to combine these datasets into a coherent testing report for each new product.

Now, the IntraStage system allows Subcom to easily view all of the previously disjointed data under one solution.

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