Increase Operational Efficiency and Improve Competitive Advantage
In casting, rolling, extrusion, and treating manufacturing operations, better process control and access to real-time, detailed production information are essential to increasing operational efficiency. The Camstar Enterprise Platform provides the visibility, control and proactive quality necessary to not only improve operational efficiency, but also raise enterprise productivity and customer satisfaction. With Camstar’s Metals Manufacturing Execution System (MES), Metals manufacturers achieve higher product quality through automated data acquisition, error prevention, and faster correlations between processes, improving Metals manufacturer’s competitive advantage.
- $7.2M ↓ annual recurring costs
- 90,000 ↑ Tonnes/year yield
- 15% ↓ cycle time
- $400K ↓ annual labor cost
- 80% ↓ inventory errors
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. Eliminate multiple manufacturing systems, plant-to-plant product variation, and siloed information by standardizing on a single, modern enterprise platform architecture. Avoid islands of information which are cumbersome to correlate, manage and maintain.
Improved Profit Margin: Grow revenues by increasing manufacturing throughput and heightening predictability of product quality to generate more accurate quantities of right final product at the right time. Simultaneously decrease costs by reducing labor, inventory, and reducing or eliminating 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.
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 real-time actionable intelligence from dashboards, preconfigured reports, and ad hoc reports correlating granular data from multiple, global, enterprise-wide sources.
Stabilized Supply Chain: Support improvements in 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 throughput, enterprise-wide enforcement, traceability, and visibility generate highly predictable output quality yielding higher customer satisfaction.
Reduced Cost & Risk of Compliance: When your final products are being delivered in regulated industries such as aerospace & defense, transportation, etc., the need to eliminate the costs associated with labor for creation, review, research, and quality control for compliance is key. 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
Increased Throughput: Significantly increase overall throughput through real-time granular visibility into manufacturing and WIP, better process enforcements, and right first time production.
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.
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 Capacity: Improve utilization of assets and human capital through real-time visibility and elimination of non-value added activities.
Improved Productivity: Eliminate or reduce non-value added compliance 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.
Decreased WIP and FG Inventory: Improved process and product visibility, multi-level tracking, reduced scrap, smaller lot sizes, and faster cycle times drive reductions in WIP and FG inventory.
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.
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”).
Benefits for Quality & Compliance
Reduced Line and Site Variability: Standardize processes across operations within a site and between sites ensuring product consistency.
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.
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.
Enforced Compliance: Ensure regulatory (military, ISO, etc.) and grade requirements are enforced across all manufacturing operations with a complete self-auditing electronic traveler for buy-offs.
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 Quality Incidents: 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.
Reduced Manufacturing Lead 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.
Benefits for IT
Full Scalability: Support frequent change and reconfiguration with an enterprise platform architecture that grows and adapts with you. Create flexible, scalable manufacturing processes that are easy to manage and are proven and reliable 24 X 365 operation.
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 global language adaptable user interface.
Reduced Total Cost of Ownership: Lower total cost of ownership with a single, modular enterprise manufacturing IT platform that eliminates disparate and redundant systems and applications increases system value. 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 process and enterprise 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: 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.
First Article Inspections: Capture additional quality parameters associated with first article inspections to support your customers quality needs.
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: Support improvements in 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: Enable true end-to-end supply chain management by removing the manufacturing ‘black hole’ and gaining complete supply chain visibility.