Industrial Manufacturing

Improving Complex Products for a Rapidly Changing World

As products increase complexity, energy and raw material costs rise, and globalization mounts, Industrial manufacturers are challenged with stabilizing profit margins, increasing manufacturing velocity and efficiency, and maintaining market share.  The Camstar Enterprise Platform provides the enterprise-wide visibility, control, and proactive quality necessary to not only overcome these challenges, but also raise productivity, enable Lean initiatives, and increase customer responsiveness.

Improve More.

  • $250K ↓ scrap on Day 2
  • 80% ↓ NCRs
  • Validated military standards compliance
  • Serialized unit traceability effort shortened from weeks to minutes
  • 2X production output

Benefits for Executives

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 scrap, labor, inventory, paper, 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.

Rapid NPI & Stabilization: Concurrent product and manufacturing process design streamlines design transfer, reduces new product ramp time, and brings innovative technologies more rapidly to market.  Global manufacturing control and enforcement reduces variability throughout the design and manufacturing processes, stabilizes the new product faster, and yields a more profitable initial launch.

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.

One Global MES: Eliminate multiple manufacturing systems, plant-to-plant product variation, and siloed information by standardizing on a single, modern enterprise platform architecture.

Reduced Cost & Risk of Compliance: Eliminate the costs associated with labor for creation, review, research, and quality control required in a paper-based traveler.  Drive tighter, enterprise-wide compliance through an electronic traveler while eliminating human errors and oversights.  The resulting proven reductions in field product quality issues, complaints, and warranty claims lower product risk and protect your brand while lowering costs strengthening market share.

Benefits for Operations

Lean Enablement: Drive lean initiatives enterprise-wide through shorter lots, automated poke-a-yoke, end-to-end process control/enforcement/visibility, electronic procedures, operator certification, machine maintenance/calibration enforcement, and integrated electronic lean workflows and kanban.

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.

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.

Improved Ramp to Volume & Line Balancing: Decrease Ramp time and improve Line Balance through process standardization, process enforcement, and real-time visibility into operations.

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.

Increased Throughput:  Significantly increase overall throughput through real-time granular visibility into manufacturing and WIP, better process enforcements, and right first time production.

Decreased WIP and FG Inventory: Improved process and product visibility, mutli-level tracking, reduced scrap, smaller lots, and faster cycle times drive reductions in WIP and FG inventory.

Improved Productivity: Eliminate or reduce non-value added traveler activities related to data collection, calculations, and documentation review.  An electronic traveler enables operators to focus time on making product rather than filling out paperwork.

Benefits for Quality & Compliance

Reduced Risk Exposure:  Systematic enforcements reduce risk by ensuring the right material with the right machine and the right data with the right operator in the right method at the right time.

Reduced Quality Incidents/Complaints/Recalls: Systematic enforcements and electronic traveler prevent quality escapes due to human error. And if the worst were to happen, recall exposure is significantly reduced via full traceability allowing for detailed recall containment of the affected – and only the affected – material.

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 Line and Site Variability: Standardize processes across operations within a site and between 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 Release Time: Rapidly release final products with fewer personnel through a self-auditing electronic traveler that allows for exception only review.

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.

Enforced Compliance: Ensure regulatory requirements (military, ISO, etc.) are enforced across all manufacturing operations with a complete self-auditing electronic traveler and Electronic Signatures.

Benefits for IT

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.

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.

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.

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.

Exceeded Expectations: Provide your stakeholders with the robust, modern IT systems that meet their needs for MES, electronic traveler, and visibility.  Satisfy their wants for ease of use and rapid configuration. Exceed their expectations with a configurable UI.

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.