Challenge:
Production was running at 40% pass rate.  Increased demand was eminent.

Solution:
Process Intellect with advanced product performance optimizers

Delivered and operating within 45 days of concept!

 

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Since these devices are so COMPLEX, the manufacturer was challenged with a very low (unacceptable) first pass rate: 40%, after assembly. Multiple sub-assemblies were being combined to create an intermediate assembly using FIFO (First In, First Out) techniques.  The objective was to increase the first pass rate as high as possible, however it must be done first on TEN product measures and later on about SIXTY!

The Methods
BioComp engineers came on site and with the customer, familiarized themselves with the process.  The key failing specifications were identified and possible causes were brainstormed.  It was obvious that the attributes of the sub-assemblies contributed to subsequent product quality, but it was the interactions that were unknown.  Additionally, certain "tunable" parameters of the assembly were available to "dial-in" results even closer to target.

Data was collected and integrated across multiple work centers about the sub-assembly attributes and 60 final assembly quality metrics from the quality management systems.  This data was modeled using BioComp's iUnderstand analysis tools to identify the key causal variables impacting quality.  A model was built for each of the 10 key attributes and over time all 60.  These models, as they were developed, were added into BioComp's Process Intellect Mix-n-Match Optimizer to seek and match optimal combinations of sub-assemblies that would maximize product performance FOR ALL ASSEMBLIES to be produced, and then "tune" them to peak performance.

Results
First pass quality test success rate went from 40% to 60% to 80% and finally 100%.  In the process, the products off the end of the line doubled, most rework eliminated and the plant experienced a significant increase in capacity just by implementing a software solution.