Case Studies > Powering innovation with actionable intelligence

Powering innovation with actionable intelligence

Company Size

1,000+

Product

InfinityQS ProFicient

Tech Stack

Statistical Process Control (SPC)
Automated Data Collection
Unified Data Repository

Implementation Scale

Departmental Deployment

Impact Metrics

Customer Satisfaction
Productivity Improvements
Waste Reduction

Technology Category

Analytics & Modeling - Predictive Analytics
Application Infrastructure & Middleware - Data Exchange & Integration
Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Consumer Goods
Electronics

Applicable Functions

Process Manufacturing
Quality Assurance

Use Cases

Machine Condition Monitoring
Predictive Maintenance
Process Control & Optimization

Services

Software Design & Engineering Services
System Integration

About The Customer

Umicore Technical Materials is a leading global provider of electrical contact materials that are essential for various everyday applications, such as lighting, electric kettles, space heaters, thermostats, and electric cars. The company is committed to creating future-oriented technologies, products, and services while maintaining the highest possible quality and efficiency to compete in the global market. Umicore's customer base is also focused on innovation, requiring the company to be a partner in their advancements. The company must adhere to strict national and international standards, including ISO 9001 and 14001, EU Directive 2002/95/ED (RoHS), EU regulation REACH, and Conflict of Materials. Umicore's internal culture emphasizes quality, tracking internal and customer complaints to identify trends and opportunities for improvement.

The Challenge

This strong customer-centric focus and drive toward futureproof technologies has produced a culture of quality at Umicore. As Quality Engineer Mark Gaumond explains: • Customers want zero defects and often require capability studies. • Processes must be stable and meet specifications that vary from customer to customer. • Umicore must meet strict national and international standards, including ISO 9001 and 14001; European Union (EU) Directive 2002/95/ED, Restriction of Hazardous Substances (RoHS); EU regulation Registration, Evaluation, Authorization and Restriction of Chemicals (REACH); and Conflict of Materials. For Umicore, quality isn’t only an external issue: It’s internal as well. Mr. Gaumond notes, “We are careful to track internal complaints, customer complaints, and internal issues so that we have a historical record to inform us about trends and opportunities for improvement and prevention.” But quality never stands still. To stay ahead of the needs of future-looking customers, Umicore needed to make quality and process control even more efficient. To do that, the company turned to InfinityQS® ProFicient™.

The Solution

Before adopting InfinityQS ProFicient, Umicore's line operators manually collected data in spreadsheets and converted it for use in a third-party data-analysis tool, which was error-prone and time-intensive. To improve quality and process control, Umicore automated data collection and centralized data storage for analysis. Working with InfinityQS, Umicore implemented ProFicient on its stamping lines, where quality is essential, and specific Statistical Process Control (SPC) requirements apply. The tolerances for the height of contact materials are extremely precise, and many process variables are in play. ProFicient ensures the critical accuracy of the stamping lines by automating data collection through the plant's existing dial indicators and micrometers. Operators simply push a button on the gauge, eliminating manual errors and streamlining data collection. The collected data is automatically stored in ProFicient's Unified Data Repository, making it easy for both operators and managers to access various charts and reports. This improved visibility into manufacturing processes helps ensure that any process changes are data-driven.

Operational Impact

Better process visibility has allowed team members to respond proactively, improving employee engagement.
Operators can see control charts on the screen, enabling them to stop the run immediately, fix issues, and restart the line, reducing waste and improving efficiency.
Operators are now more comfortable making corrections to improve the final product.
Umicore can supply customers with verification data and detailed product information at any time, thanks to centrally stored data.
The company plans to expand its use of ProFicient to additional process lines and run it over the local area network to increase system availability across the plant.