Rolls-Royce (formerly Controls and Data Services)
safety critical controls and asset intelligence solutions for industrial power, marine, civil, and military aerospace
“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
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
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