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Recasting a High-end Foundry into a Data-driven Manufacturer
Technology Category
- Analytics & Modeling - Real Time Analytics
- Application Infrastructure & Middleware - Data Exchange & Integration
- Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
- Automotive
- Aerospace
- Semiconductors
Applicable Functions
- Quality Assurance
- Process Manufacturing
- Product Research & Development
Use Cases
- Predictive Maintenance
- Machine Condition Monitoring
- Process Control & Optimization
- Supply Chain Visibility
Services
- System Integration
- Software Design & Engineering Services
- Training
The Challenge
Palmer Foundry faced significant challenges in meeting customer quality assurance guidelines due to data being scattered across multiple spreadsheets and laptops, making it difficult to access and analyze. The company also had limited statistical process control (SPC) skills and an overburdened IT department, which made the introduction of new software a concern. Despite their success in delivering high-quality products, Palmer needed to prove their quality control processes to meet industry guidelines and customer requirements. They saw an opportunity to adopt a manufacturing intelligence system to improve decision-making and business strategy.
About The Customer
Palmer Foundry, located in Massachusetts, specializes in designing and manufacturing high-end, precision aluminum castings for various industries, including semiconductor, automotive, energy, aerospace, and robotics. The foundry is known for its demanding specifications and diligent control of raw materials and processes. Despite their success and customer satisfaction, Palmer faced pressure from existing and prospective customers to meet stringent quality assurance guidelines. The company realized the need to prove their quality control processes and saw an opportunity to adopt a manufacturing intelligence system to enhance their decision-making and business strategy.
The Solution
Palmer Foundry implemented NWA Focus EMI® from Northwest Analytics, a full-featured manufacturing intelligence solution. The installation was completed over the phone, and within three weeks, Palmer was operating with direct data-source connectivity, global analytics, real-time role-based visualization, and alarm notification services. NWA Focus EMI allowed Palmer to access data directly from original sources, pass it through a global analytics layer, and deliver actionable information through an intelligence viewer. This provided Palmer with real-time information, visual displays, and a color-coded warning system for deviations from project or raw materials parameters. The solution enabled Palmer to validate raw materials, gain greater process visibility and control, and provide documented process quality control data to customers.
Operational Impact
Quantitative Benefit
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