Recasting a High-end Foundry into a Data-driven Manufacturer

技术

分析与建模 - 实时分析
应用基础设施与中间件 - 数据交换与集成
功能应用 - 制造执行系统 (MES)

适用行业

汽车
航天
半导体

适用功能

质量保证
流程制造
产品研发

用例

预测性维护
机器状态监测
过程控制与优化
供应链可见性(SCV)

服务

系统集成
软件设计与工程服务
培训

挑战

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.

关于客户

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.

解决方案

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.

运营影响

Palmer Foundry transformed into a data-driven organization, leveraging consistent data, automated global analytics, and real-time actionable information.
The company gained the ability to validate raw materials before they entered the manufacturing line, preventing disruptions and allowing for adjustments to accommodate material variables.
Palmer achieved greater real-time control over manufacturing processes, preventing costly end-product issues and enabling immediate action to control scrap and rework rates.

数量效益

$1.4M new business won in the first year showcasing capabilities with NWA Focus EMI.
$70K saved by avoiding a single product recall event.
7% decrease in scrap rate.