Case Studies > Chips Aren't Cheap

Chips Aren't Cheap

Company Size

1,000+

Region

America

Country

United States

Product

GainSeeker Suite

Tech Stack

Statistical Process Control (SPC) Software
Real-time Data Acquisition
Analytics Software

Implementation Scale

Enterprise-wide Deployment

Impact Metrics

Cost Savings
Customer Satisfaction
Productivity Improvements

Technology Category

Analytics & Modeling - Predictive Analytics
Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Consumer Goods
Semiconductors

Applicable Functions

Process Manufacturing
Quality Assurance

Use Cases

Machine Condition Monitoring
Predictive Maintenance
Process Control & Optimization

Services

Software Design & Engineering Services
System Integration
Training

About The Customer

Hertzler Systems has been a leader in Statistical Process Control, SPC Software, and Six Sigma for over twenty-five years. They provide the leading real-time data acquisition and analytics SPC software, the GainSeeker Suite. Hertzler Systems serves a diverse customer base, including BAE Systems, Crown International, McCormick & Company, Inc., Hormel Foods Corporation, Snyders of Hanover, TaylorMade-Adidas Golf Worldwide, and Rolls-Royce Corporation. Their software and services enable clients to connect, collect, analyze, and visualize data, building a data infrastructure for making data-driven decisions. These capabilities help clients improve throughput and yield, improve cycle times, reduce costs and errors, and increase profitability.

The Challenge

The Plant Manager for a chip manufacturing company is responsible for cost management, efficiency, and overall profitability. Chips aren’t cheap and neither are the film bags they come in. Although every chip that gets overfilled in the bag costs almost nothing, given the volume of production a year, it adds up quickly. An even greater cost are the film bags that get damaged during production and aren’t able to be used. Producing so many bags a year means that the slightest change in the production has a dramatic impact on net income. Maximizing production while decreasing costs is a daunting task, especially when the bag sizes are getting smaller and smaller, leaving less room for error. The Plant Manager wanted to be able to monitor the overfill of chips and the film wastes of bag production. It was necessary to educate the workers on NIST 133 and to keep them accountable for monitoring these signals in order to increase profits while meeting standards.

The Solution

Hertzler Systems provided their GainSeeker Software to the chip manufacturing company. The software offered scorecards for each worker after each shift to gain accountability and visibility for how they monitor and track their product weights and film usage. This solution allowed the Plant Manager to monitor the overfill of chips and the film wastes of bag production effectively. The software also helped in educating the workers on NIST 133 standards and keeping them accountable for monitoring these signals. By implementing GainSeeker, the company was able to increase profits while meeting industry standards. The real-time data acquisition and analytics capabilities of GainSeeker enabled the company to make data-driven decisions, thereby improving their overall efficiency and profitability.

Operational Impact

GainSeeker Software provided scorecards for each worker after each shift, enhancing accountability and visibility.
The software helped in educating workers on NIST 133 standards, ensuring they were accountable for monitoring signals.
The real-time data acquisition and analytics capabilities enabled the company to make data-driven decisions.
The solution allowed the Plant Manager to effectively monitor the overfill of chips and the film wastes of bag production.
The company saw a return on investment in well under a year and will continue to see great savings in the future.

Quantitative Benefit