Meeting Client Needs
At Savigent Software, we seek to develop and provide tailored software solutions to meet client needs. We take great pride in finding answers to complex automation challenges. The following case studies offer a glimpse of our approach to working with a variety of clients.
Savigent Historian™ Helps Uponor Focus on Continuous Improvement
Background: Apple Valley, Minn.-based Uponor North America (Uponor NA) is a leading supplier of plumbing, fire sprinkler, and radiant heating and cooling systems for residential and commercial spaces worldwide. The North American headquarters employs 380 people and houses corporate offices and a state-of-the-art training center. It is also home to a manufacturing facility that produces thousands of feet of cross-linked polyethylene (PEX) tubing every day for use in those plumbing, fire sprinkler, and radiant heating and cooling systems.
This case study provides an overview of Savigent Software’s implementation Savigent Historian™ and use of data collection to drive continuous improvement initiatives. At Uponor, Savigent Historian™ provides a comprehensive solution for manufacturing data collection, storage, contextualization and analysis. The system serves as a common, centralized repository for key performance indicator (KPI) data for Uponor’s entire manufacturing operation. Continuous improvement initiatives underway at Uponor leverage the data provided by the system for decision support. The case study highlights Uponor’s experiences improving equipment performance, driving higher overall equipment effectiveness (OEE) and reducing scrap rates.
Semiconductor Maker Improves Lithography Overlay Performance through Workflow Automation based Run-to-Run Control
Background: A U.S-based semiconductor manufacturer, operating a 200,000 square-foot facility that includes 62,000 square feet of cleanroom space for wafer fabrication, was in pursuit of better control of its processes. To that end, this semiconductor manufacturer worked with Savigent Software, using Savigent Workflow™ (workflow automation software) to take run-to-run control to new levels of efficiency in improving its overlay control (i.e. registration) process. The semiconductor makers manufacturing facilities include a six-inch (150mm) and an eight-inch (200mm) wafer fab.
This case study provides an overview of Savigent Software’s implementation of run-to-run control using Savigent Workflow™. Run-to-run control provides manufacturers with the ability to automatically adjust equipment recipe settings “run-to-run” in an effort to minimize the variability of process performance. Equipment recipe settings are adjusted in advance of processing based on a set of contextually relevant data, such as measurements from similar products previously produced.
Experience of World-Class Electronics Manufacturer Validates Workflow Automation in High Tech Manufacturing
Background: Savigent Workflow™ is the comprehensive, integrated workflow automation system implemented within the global semiconductor fabrication operations at one of the world’s leading electronics manufacturers. The system is central to the company’s factory control strategy and has helped solve a wide range of problems by automating processes that include: real time analysis of manufacturing data, custom diagnostics and documentation, request systems, and out-of-control action plans (OCAPS).
This case study provides an overview of Savigent Software’s implementation of Savigent Workflow™ at this leading electronics manufacturer. Additional case studies focused on the implementation of automated OCAPS, request systems and equipment management solutions can be found below.
Savigent Reduces Downtime and Variability by Automating OCAPS
Background: When one of the world’s leading electronics manufacturers investigated the automation of workflows in their factories, automating out-of-control action plans (OCAPS) was identified as the largest opportunity for return on investment. An OCAP is the process flow for understanding and mitigating failures at any given stage or tool in the production process. In developing an overarching system for their manufacturing environment, the company leveraged Savigent Workflow™ to provide the basis for a controlled system of workflow automation.
This case study shows how Savigent Workflow™ is enabling the transition away from paper-based procedures to automated OCAPS, optimizing and standardizing responses to critical manufacturing events. The resulting pit crew like response comes with a significant ROI based on improved resource utilization and higher tool uptime.
Get the Job Done Faster and More Efficiently with Request Systems
Background: One of the world’s leading electronics manufacturers was facing a problem indigenous to manufacturers in many markets: everyone in the factory wanted to get their jobs done. Within the organization, different groups were developing different “request systems” to get their jobs done. What the company wanted and needed was one overarching request system. Savigent implemented a Savigent Workflow™ based request system delivering guaranteed compliance with standard operating procedures, excellent traceability, and rich manufacturing data previously unavailable without an extraordinary, time-consuming, and costly effort.
This case study highlights the use of Savigent Workflow™ to orchestrate and optimize largely people-based operations through the implementation a request system. The results show remarkable improvements in execution cycle time. There is an increased focus on getting the right jobs done correctly and efficiently, because the work and how it is done is measurable.
Automating Workflows to Optimize Factory Performance
Background: Until about a year and a half ago, one of the world’s leading electronics manufacturers had an equipment qualification process that was largely controlled by paper procedures and coordinated by word of mouth. The company engaged Savigent to address this issue by automating equipment-centric processes using Savigent Workflow™. The resulting system leverages the model-based flexibility of Savigent Workflow™ to provide engineers a workflow development environment that they can use to easily build workflows on their own.
This case study explains how Savigent Workflow™ is being used to manage equipment related processes in a highly capital intensive operation where exact execution is essential. The reduced equipment downtime and improved conformance are saving the company enormous sums.
Logic PD’s Implementation of Savigent Workflow™ Brings the Power of IT to the Manufacturing Floor
Background: Logic PD understands the need to innovate. Based in Eden Prairie, Minn., the global product development and manufacturing provider works under the banner of “innovative product solutions.” Its ability to bring ideas forward from the back burner has made it one of the nation’s best and brightest product realization companies. As a strategic partner, Logic PD works with its clients to leverage intellectual property that may not have seen the light of day otherwise. But as these successes grow, so can the pressure on Logic PD’s manufacturing operations. It’s a natural challenge for growing manufacturers.
This case study provides an overview of Savigent Software’s implementation of Savigent Workflow™ at Logic PD. The system fully automates Logic PD’s tracking and control of its box-build processes. Savigent Workflow™ was introduced on a manufacturing line that has ten steps from the production request to the bulk packaging of the finished goods. It enforces compliance to the defined manufacturing standard — virtually error-proofing operations. The new system empowers Logic PD to scale faster, bring products to market more rapidly, increase customer visibility, and improve overall manufacturing efficiencies.
Leveraging Workflow Automation in the Batch Environment
Background: The HallStar Company knows about building out functionality. Based in downtown Chicago, with its principal manufacturing and technical center just west of the city’s Midway International Airport, HallStar has been manufacturing specialty chemicals for over 50 years. Today, it is one of the world’s experts in the development and formulation of esters for the polymer and personal care markets.
This case study provides an overview of Savigent Software’s implementation of Savigent Workflow™ and Savigent Historian™ at Hallstar. The system provides the ability to fully automate batch execution and electronic batch record management as well as the ability to collect key manufacturing intelligence related to plant asset management. Savigent Workflow™ executes batch production recipes, manages unit operations and automates standard operating procedures that make up the batch manufacturing process. Savigent Historian™ is incorporated to capture key process indicators and production tracking information.
Savigent Automates Equipment Utilization
Background: Tampa, Fla.-based Anchor Glass Container Corporation (Anchor) is a hallmark name in America’s packaging industry as a leading and long-established manufacturer of glass containers. Anchor produces a diverse line of flint, amber, green, and other colored glass containers of various types and designs primarily for the beer, food, beverage, liquor, and consumer product industries.
This case study provides an overview of Savigent Software’s asset utilization and production reporting features and capabilities. By running Savigent Platform™, Anchor Glass now compiles faster, more accurate production data, which extends visibility of that data to all areas of manufacturing facility.
Compressed Air Control System
Background: This automotive assembly plant was using over 40,000 killowatt hours of electricity during daily production to generate the compressed air needed for assembly operations. At $0.05 per kilowatt hour this amounted to about $2,000 per day. In addition the compressed air system was unreliable and prone to failures that would completely stop the assembly lines. This resulted in a production loss that equaled one vehicle per minute during peak production. If the price of that vehicle was $20,000, a 10-minute outage would cost as much as $200,000.
Inline Metrology System
Background: This semiconductor manufacturer was scrapping too many wafers late in their recording head production process. Savigent software was used to enable an inline metrology step with the primary purpose of identifying indicators of scrap at a step where rework was still an option, therefore reducing scrap costs dramatically.
Pump Monitoring System
Background: This semiconductor manufacturer utilizes over 200 cryopumps during manufacturing operations. Cryopumps represent a significant hardware investment and a critical process step in this manufacturer’s operations, so keeping them running correctly is critical to efficient operations and maintaining a low scrap rate.
Target Maintenance Tracker
Background: This manufacturing operation uses over 200 disparate tools that all require scheduled maintenance based on usage data such as the number of kilowatt hours or number of units produced since the last scheduled maintenance. Failure to do this preventative maintenance produces a costly increase in scrap. Usage data is periodically collected manually off of each machine and logged into spreadsheets. Engineers then compare this usage data to a maintenance schedule for a particular machine to determine whether maintenance is needed.