"As an engineer, I have been using STATISTICA for over 15 years and it has provided me with a wide range of analytical capabilities...In one instance, I was able to model industrial aluminum alloys heat treating and reduce the furnace cycle time by 54%, saving energy and increasing productivity."
— Hélène Lagacé
Lean Six Sigma Master Black Belt
February 10, 2013
In manufacturing, analytics need to be fast and straightforward, integrated with your company’s data repositories, so that they can be applied on an ongoing basis for continuous process improvement. Companies using STATISTICA analytic solutions benefit from having all of the stages of analytics in one software platform. STATISTICA is personalized, delivering the workflows, reports, dashboards, etc., specific to the role and responsibility of each person.
Manufacturing today is a complicated business with many challenges:
Manufacturing processes can be complex. Often there are several process steps, assembly steps, and test steps. Various raw materials and subassemblies from an assortment of suppliers are brought together to deliver a finished product. Key questions are:
STATISTICA provides a suite of tools for root cause analysis, empowering engineers and other quality professionals with the capabilities for quickly identifying the few important factors from the many.
Using root cause analysis analytics in STATISTICA, manufacturers have uncovered process understanding that was previously not possible.
Opportunities for cost savings include:
Once the critical few inputs impacting product quality are known, analytics in STATISTICA provide predictive models that characterize the processes. The predictive models make product quality predictions for various settings of the process, enabling ‘what if?’ scenarios to be performed by the engineering team to determine how the process behaves.
The next logical question is “What should the inputs be and how should our manufacturing processes be run to achieve the most cost effective and robust product quality outcomes?” STATISTICA provides structured tools and processes for engineers to perform process optimization. Engineers utilize their subject matter expertise to define which parameters are easy to change or expensive to change. Engineers are able to interact with and scrutinize these recommendations to assess predicted versus current process performance, including % beyond specifications and Cpk/Ppk, to estimate the cost savings and expected product quality improvements. Engineering user interfaces result in recommendations that are target optimal ranges for all of the critical variables, including raw materials or other inputs, that become the values for the limits for process monitoring.
With Multivariate SPC methods, you can find anomalies in high-dimensional data that otherwise are not visible. When looking at each dimension by itself, many anomalies or manufacturing defects are hidden and missed. Incorporate Multivariate Statistical Process Control:
Root cause analysis and process optimization define the most critical parameters driving product quality outcomes and what settings should be used to achieve repeatable and robust product quality outcomes, even with the expected variability in the other aspects of the manufacturing processes. These results feed directly into process monitoring, providing the definition of what to monitor and what values to apply as warning and control limits.
Unique in the STATISTICA approach to statistical process control are at least three major factors:
Most manufacturers have a complex supply chain including numerous suppliers. Monitoring the operations and quality of suppliers is a common problem. With STATISTICA, Supplier Quality Monitoring enables immediate insight into how your company’s suppliers are doing by:
In STATISTICA, manufacturers configure secure, limited access to the latest status reports for their customers. Allow your customers to have Web-based secure access to review reports so they can self-service. Differentiate from your competitors by delivering transparency into your manufacturing operations. Save costs by automating these reports rather than reacting to customer requests for data and status reports. Customers may be external customers or internal stakeholders from processes later in your company’s supply chain.
The STATISTICA platform includes data entry, providing complete flexibility in defining the data entry scenarios for each cell or unit operation. Easy-to-use Web-based data entry forms are configured specific to each data entry scenario. The data are stored in a standard relational database, completely integrated with the analytic capabilities and reports of the STATISTICA platform.
Configure, publish, and monitor Web-based dashboards of key performance indicators. Deliver relevant information directly to the stakeholders, everyone from the shop floor to management.
STATISTICA Dashboards are completely configurable. Examples include summaries of throughput metrics, tracking of rework and scrap, Cpk/Ppk summaries, and pareto charts of defects.
Flex2000 Implements STATISTICA Enterprise for Quality Assurance and Process Improvement
STATISTICA Enterprise helps Delphi Save Significant Time for its Statistical Process Control and Six Sigma Applications
Online Test Monitoring System Created by PDC Internet Solutions and StatSoft Ltd for CEC, using STATISTICA Enterprise Server