State-of-the-Art MES for Increasing Complexity, Competition, and Demand
Electronics manufacturers face tough challenges ahead from dramatic increases in competition, product complexity, and final product demand. Camstar’s Electronics Manufacturing Execution System allows manufacturers to change and reconfigure the manufacturing & quality processes at the speed required to meet increased customer demand and quality requirements regardless of product complexity and plant location. Using the Camstar Enterprise Platform, manufacturers can standardize, define and enforce manufacturing and quality processes globally across multiple sites to produce the highest product quality while reducing costs.
- 50% ↓ material usage errors
- > 5% ↑ yield on most machines
- 25% ↑ units shipped per quarter
- 30-50% ↓ cost and time of subsequent plant MES roll-out
- > 5% ↑ efficiency most work stations
Benefits for Executives
One Global MES: Eliminate multiple legacy systems, plant-to-plant product variation, and siloed information by standardizing on a single, modern enterprise platform architecture. With Camstar, you can support change management by centrally authoring manufacturing process changes once and deploying them globally to one site or many, saving time and increasing consistency across your enterprise.
Protected Future with Modern Systems: Eradicate the corporate and brand risk exposure from numerous legacy systems and applications that are reaching end-of-life. Position for future growth and greater market share with a scalable, adaptable, modern MES.
Rapid NPI & Stabilization: Streamline design processes with concurrent product and process design transfer reducing new product ramp time, and bringing innovative technologies more rapidly to market.Effective change management is essential to gaining process control and enforcement, significantly reducing variability. Camstar provides this control with centralized authorship of manufacturing process changes that can be rapidly and accurately deployed across your enterprise, allowing you to improve time to market without sacrificing quality.
Global Visibility & Reporting: View in real-time, reliable enterprise-wide data comparing plant-to-plant, line-to-line, and shift-to-shift performance. Utilize native, robust dashboard capabilities to provide relevant, real-time information to every stakeholder from Executives to Machine Operators.
Enhanced Decision Making: Improve your decision making capabilities by gaining actionable intelligence from dashboards, preconfigured reports, and ad hoc reports correlating granular data from multiple, global, enterprise-wide sources.
Stabilized Supply Chain: Improve planning and scheduling with real-time plant information. Diminish upstream and downstream supply chain disruptions through complete product and process enforcement and traceability. Joined with increased manufacturing velocity, enterprise-wide enforcement, traceability, and visibility generate highly predictable output quality yielding higher customer satisfaction.
Improved Profit Margin: Grow revenues by increasing manufacturing velocity and heightening predictability of product quality to generate larger quantities of final product. Simultaneously decrease costs by reducing or eliminating paper, scrap, labor, inventory, and non-value added activities. The concurrent effects of an enterprise-wide system increasing revenues and reducing costs improve the profit margin at the most rapid rate – meeting or exceeding shareholder/investor expectations.
Benefits for Operations
Global Product & Process Traceability: Trace any product, lot or unit and its processes across the supply chain, a factory, multiple factories, or the entire enterprise. Traceability data includes backwards and forwards genealogy of materials consumed, processes and equipment utilized, parametric and quality data collected, exceptions, rework, dates and times, and electronic signatures.
Increased Product & Process Yield: Reduce scrap and rework and improve first pass yield through systematic product/process enforcements by enforcing accurate data collections, usage of only authorized materials, utilization of the right procedures and equipment, certification of operators, and more.
Improved Productivity: Eliminate or reduce non-value added activities.
Increased Throughput: Significantly increase overall throughput through real-time granular visibility into manufacturing and WIP, better process enforcements, and right first time production.
Reduced Costs: Lower the costs of poor quality and good quality in manufacturing through reduction and/or redeployment of manpower, elimination of paper records (e.g., scanning, storage, paper, ink), and error proofing at each step of the process (automated “poke-a-yoke”).
Increased Capacity: Improve utilization of assets and human capital through real-time visibility and elimination of non-value added activities.
Improved Ramp to Volume & Line Balancing: Decrease Ramp time and improve Line Balance through process standardization, process enforcement, and real-time visibility into operations. Support manufacturing changes by centrally authoring manufacturing process changes once and deploying them globally to one site or many, saving time and increasing consistency across your enterprise.
Decreased WIP and FG Inventory: Improve process and product visibility, with multi- level tracking, reduced scrap, smaller lots, and faster cycle times drive reductions in WIP and FG inventory.
Benefits for Quality & Compliance
Better Product & Process Design: Receive accurate data on product and process performance information, actual occurrence rate of failure modes, identification of common failures by product/process, and via collaboration with product and process engineers.
Reduced Risk Exposure: Reduce risk with systematic enforcement and forward and backward genealogy that assures your operator has the material, process parameters and data to make real time, in-line decisions.
Reduced Line and Site Variability: Standardize processes across operations within and among sites ensuring product consistency.
Better Traceability: Search across all manufacturing and quality related data related to a work order, lot, unit, operator, material, piece of equipment, etc. in a matter of seconds.
Reduced Quality Incidents/Complaints/Recalls: Prevent quality escapes due to human error with systematic enforcements. And if the worst were to happen, reduce recall exposure with full traceability allowing for detailed recall containment of the affected – and only the affected – material.
Faster & Accurate Impact Analysis: Search and filter for suspect lots/units based on criteria such as component lots/sub-assemblies, equipment used, revision of specifications, and operators.
Benefits for IT
Flexibility: Easily configure and reconfigure any process from PCBA to Final Assembly and Inspection without coding via configuration
Adaptable UIs: Easily and rapidly configure user interfaces for each stakeholder that match the way they work. Increasing user speed and eliminating unnecessary steps during manufacturing. Support global operations worldwide with a language adaptable user interface.
Full Scalability: A complete enterprise platform architecture for manufacturing, quality, and intelligence that grows and adapts with you. Support frequent change and reconfiguration – managed by users. Assure your company with top performance and 24 X 365 reliability.
Performance: Proven ability to support high volume transactions, tested up to 700 MES transactions per second.
Shop Floor to Top Floor Visibility: Utilize native, robust dashboard capabilities to provide relevant, real-time information to every stakeholder from Executives to Machine Operators.
Single Manufacturing Standard: Standardize IT systems across all operations, accounting for and better enabling multiple concurrent manufacturing processes and assets.
Reduced Total Cost of Ownership: A single, modular enterprise manufacturing IT platform eliminates disparate and redundant systems and applications increasing system value while lowering total cost of ownership. Further reduce costs with significant out-of-the-box functionality and best practices avoiding custom coding and development.
Business Process Interoperability: Electronics Suite creates an enterprise manufacturing hub that aggregates real-time production data for collaboration within the business and with suppliers and customers. It integrates easily with ERP and PLM applications for synchronizing products, bills of materials and manufacturing specifications; providing timely and accurate work-in-process information for improving designs, quality, inventory, processes, planning and financial analysis.
Benefits for R&D and Engineering
Rapid NPI & Stabilization: Concurrent product and manufacturing process design streamlines design transfer reducing new product ramp time bringing innovative technologies more rapidly to market. Reducing variability throughout the design and manufacturing processes stabilizes the new product faster yielding a more profitable initial launch.
Enhanced Modeling & Testing: Accurately understand manufacturing capabilities through integrated modeling and testing that leverages manufacturing and product past performance. Eliminate many variables in your next new product introduction.
ECO Visibility & Performance: Understand the impact in real-time of systemically enforcing an engineering change order (ECO). View performance impact immediately, prevent/control downstream effects, and verify post-change results through effectivity monitoring and system alerts.
Benefits for the Supply Chain
Stabilized Supply Chain: Improve supply chain planning and scheduling with real-time plant information. Diminish upstream and downstream supply chain disruptions through complete product and process enforcement and traceability. Joined with increased manufacturing velocity, enterprise-wide enforcement, traceability, and visibility generate highly predictable output quality yielding higher customer satisfaction.
Visible Supply Chain: Complete supply chain visibility by removing the manufacturing ‘black hole’. Enable true end-to-end supply chain management.