Case Studies Recasting a High-end Foundry into a Data-driven Manufacturer

Edit This Case Study Record

	Recasting a High-end Foundry into a Data-driven Manufacturer

Recasting a High-end Foundry into a Data-driven Manufacturer

Technology Category	Analytics & Modeling - Real Time Analytics Application Infrastructure & Middleware - Data Exchange & Integration Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries	Aerospace Automotive Semiconductors
Applicable Functions	Process Manufacturing Product Research & Development Quality Assurance
Use Cases	Machine Condition Monitoring Predictive Maintenance Process Control & Optimization Supply Chain Visibility
Services	Software Design & Engineering Services System Integration Training
Challenge	Palmer Foundry faced significant challenges in meeting customer quality assurance guidelines due to data being scattered across multiple spreadsheets and laptops, making it difficult to access and analyze. The company also had limited statistical process control (SPC) skills and an overburdened IT department, which made the introduction of new software a concern. Despite their success in delivering high-quality products, Palmer needed to prove their quality control processes to meet industry guidelines and customer requirements. They saw an opportunity to adopt a manufacturing intelligence system to improve decision-making and business strategy. Read More
About Customer	Palmer Foundry, located in Massachusetts, specializes in designing and manufacturing high-end, precision aluminum castings for various industries, including semiconductor, automotive, energy, aerospace, and robotics. The foundry is known for its demanding specifications and diligent control of raw materials and processes. Despite their success and customer satisfaction, Palmer faced pressure from existing and prospective customers to meet stringent quality assurance guidelines. The company realized the need to prove their quality control processes and saw an opportunity to adopt a manufacturing intelligence system to enhance their decision-making and business strategy. Read More
Solution	Palmer Foundry implemented NWA Focus EMI® from Northwest Analytics, a full-featured manufacturing intelligence solution. The installation was completed over the phone, and within three weeks, Palmer was operating with direct data-source connectivity, global analytics, real-time role-based visualization, and alarm notification services. NWA Focus EMI allowed Palmer to access data directly from original sources, pass it through a global analytics layer, and deliver actionable information through an intelligence viewer. This provided Palmer with real-time information, visual displays, and a color-coded warning system for deviations from project or raw materials parameters. The solution enabled Palmer to validate raw materials, gain greater process visibility and control, and provide documented process quality control data to customers. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Real Time Analytics

Application Infrastructure & Middleware - Data Exchange & Integration

Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Aerospace

Automotive

Semiconductors

Applicable Functions

Process Manufacturing

Product Research & Development

Quality Assurance

Use Cases

Machine Condition Monitoring

Predictive Maintenance

Process Control & Optimization

Supply Chain Visibility

Services

Software Design & Engineering Services

System Integration

Training

Challenge

Palmer Foundry faced significant challenges in meeting customer quality assurance guidelines due to data being scattered across multiple spreadsheets and laptops, making it difficult to access and analyze. The company also had limited statistical process control (SPC) skills and an overburdened IT department, which made the introduction of new software a concern. Despite their success in delivering high-quality products, Palmer needed to prove their quality control processes to meet industry guidelines and customer requirements. They saw an opportunity to adopt a manufacturing intelligence system to improve decision-making and business strategy.

About Customer

Palmer Foundry, located in Massachusetts, specializes in designing and manufacturing high-end, precision aluminum castings for various industries, including semiconductor, automotive, energy, aerospace, and robotics. The foundry is known for its demanding specifications and diligent control of raw materials and processes. Despite their success and customer satisfaction, Palmer faced pressure from existing and prospective customers to meet stringent quality assurance guidelines. The company realized the need to prove their quality control processes and saw an opportunity to adopt a manufacturing intelligence system to enhance their decision-making and business strategy.

Solution

Palmer Foundry implemented NWA Focus EMI® from Northwest Analytics, a full-featured manufacturing intelligence solution. The installation was completed over the phone, and within three weeks, Palmer was operating with direct data-source connectivity, global analytics, real-time role-based visualization, and alarm notification services. NWA Focus EMI allowed Palmer to access data directly from original sources, pass it through a global analytics layer, and deliver actionable information through an intelligence viewer. This provided Palmer with real-time information, visual displays, and a color-coded warning system for deviations from project or raw materials parameters. The solution enabled Palmer to validate raw materials, gain greater process visibility and control, and provide documented process quality control data to customers.

Impact #1	Palmer Foundry transformed into a data-driven organization, leveraging consistent data, automated global analytics, and real-time actionable information.
Impact #2	The company gained the ability to validate raw materials before they entered the manufacturing line, preventing disruptions and allowing for adjustments to accommodate material variables.
Impact #3	Palmer achieved greater real-time control over manufacturing processes, preventing costly end-product issues and enabling immediate action to control scrap and rework rates.

Impact #1

Palmer Foundry transformed into a data-driven organization, leveraging consistent data, automated global analytics, and real-time actionable information.

Impact #2

The company gained the ability to validate raw materials before they entered the manufacturing line, preventing disruptions and allowing for adjustments to accommodate material variables.

Impact #3

Palmer achieved greater real-time control over manufacturing processes, preventing costly end-product issues and enabling immediate action to control scrap and rework rates.

Benefit #1	$1.4M new business won in the first year showcasing capabilities with NWA Focus EMI.
Benefit #2	$70K saved by avoiding a single product recall event.
Benefit #3	7% decrease in scrap rate.

Benefit #1

$1.4M new business won in the first year showcasing capabilities with NWA Focus EMI.

Benefit #2

$70K saved by avoiding a single product recall event.

Benefit #3

7% decrease in scrap rate.

Download PDF Version

Overview

Recasting a High-end Foundry into a Data-driven Manufacturer

Operational Impact

Quantitative Benefit