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Chips Aren't Cheap
Technology Category
- Analytics & Modeling - Predictive Analytics
- Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
- Semiconductors
- Consumer Goods
Applicable Functions
- Quality Assurance
- Process Manufacturing
Use Cases
- Predictive Maintenance
- Machine Condition Monitoring
- Process Control & Optimization
Services
- Software Design & Engineering Services
- System Integration
- Training
The Challenge
The Plant Manager for a chip manufacturing company is responsible for cost management, efficiency, and overall profitability. Chips aren’t cheap and neither are the film bags they come in. Although every chip that gets overfilled in the bag costs almost nothing, given the volume of production a year, it adds up quickly. An even greater cost are the film bags that get damaged during production and aren’t able to be used. Producing so many bags a year means that the slightest change in the production has a dramatic impact on net income. Maximizing production while decreasing costs is a daunting task, especially when the bag sizes are getting smaller and smaller, leaving less room for error. The Plant Manager wanted to be able to monitor the overfill of chips and the film wastes of bag production. It was necessary to educate the workers on NIST 133 and to keep them accountable for monitoring these signals in order to increase profits while meeting standards.
About The Customer
Hertzler Systems has been a leader in Statistical Process Control, SPC Software, and Six Sigma for over twenty-five years. They provide the leading real-time data acquisition and analytics SPC software, the GainSeeker Suite. Hertzler Systems serves a diverse customer base, including BAE Systems, Crown International, McCormick & Company, Inc., Hormel Foods Corporation, Snyders of Hanover, TaylorMade-Adidas Golf Worldwide, and Rolls-Royce Corporation. Their software and services enable clients to connect, collect, analyze, and visualize data, building a data infrastructure for making data-driven decisions. These capabilities help clients improve throughput and yield, improve cycle times, reduce costs and errors, and increase profitability.
The Solution
Hertzler Systems provided their GainSeeker Software to the chip manufacturing company. The software offered scorecards for each worker after each shift to gain accountability and visibility for how they monitor and track their product weights and film usage. This solution allowed the Plant Manager to monitor the overfill of chips and the film wastes of bag production effectively. The software also helped in educating the workers on NIST 133 standards and keeping them accountable for monitoring these signals. By implementing GainSeeker, the company was able to increase profits while meeting industry standards. The real-time data acquisition and analytics capabilities of GainSeeker enabled the company to make data-driven decisions, thereby improving their overall efficiency and profitability.
Operational Impact
Quantitative Benefit
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