Rolls-Royce

CASE STUDY

Formerly Controls and Data Services.

Safety critical controls and asset intelligence solutions for industrial power, marine, civil, and military aerospace.

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.

Solution:

Implementation of IntraStage BlackBelt Manufacturing for automated Data Management.

Robust data model enabling OLAP Cube Analytics.

Out of the Box Quality Reports
Open system enabling custom report development and Enterprise Integration.

Benefits:

£500,000/(year over year) savings since 2005
Predictive Analysis on Key Process Variables using SPC
Reduced time for defect analysis from two weeks down to seconds
Dramatically improved throughput yield and cycle time

“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.

“A testimonial from Viasat will go here. The copy will be copy fitted to take up this much space in this area. A quote from the person providing the testimonial will go here and take up this much space.”

– The Person’s Job Title Will Go Here

CASE STUDY:

Challenge:

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.

“In less than one week, we had identified the problem by being able to mine and visualize previous test results that IntraStage had gathered automatically. Without IntraStage, this would have taken us months and lots of frustration.”

– Test Manager

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