Case Study
Digital Factory Transformation with 35,000 Pieces of Manufacturing Equipment Connected in the Cloud
The Challenge
Sanmina manufactures 250 million products per year. More of a challenge is that there are over 200,000 different top-level assemblies produced each year for 700 different OEM customers with up to 20,000 forecast changes per week. The OEMs operate in diverse industries including telecommunications, enterprise computing & storage, and industrial and clean technology. A significant amount of production is for medical, aerospace and automotive products with strict regulatory requirements. The existing on-premise MES required significant maintenance and upgrade efforts from the IT and operations teams. It was also limited in its ability to manage supply chains beyond the walls of each factory, and was not well suited for factory automation and other IIoT Initiatives.
Why 42Q
42Q offers a full-featured global cloud-based system capable of integrating product yield, WIP and inventory information across a global network of 10,000 suppliers delivering components to 50 manufacturing facilities in 15 countries around the world. Many of these factories supply sub-assemblies to PCBA and systems integration facilities. The solution accommodated Sanmina’s diverse manufacturing processes including enclosure fabrication, PCBA manufacturing and complex systems integration. It also complies with regulatory requirements in medical, aerospace and automotive industries.
Solution
- A unified virtual cloud factory (digital twin) provides global factory and supply chain visibility, including real-time WIP, yield and throughput data for 50 factories.
- Following implementation, plants self deployed the cloud-based MES with no support from I.T. or 42Q. Because of this, 42Q was rapidly adopted and its use expanded.
- A visual factory monitors yield, throughput, work-in-process (WIP) ageing, against predefined targets. It provides real-time status at product, workstation, production floor, plant, regional and global levels.
- Production lines in 42Q are programmed so alerts are sent to technicians, engineers or management when WIP, yields or throughput drops below predefined limits.
- Multi-level supply chain visibility provides real-time component delivery information from suppliers, real-time status on work orders in factories manufacturing sub-assemblies including PCBs, enclosures and PCBAs.
See How Our Customers are
Transforming Their Businesses
Weir Minerals Reduces Manufacturing Lead Times by up to 30%
Weir Minerals, a part of the Weir Group plc, is a global market leader in the supply of engineered solutions and aftermarket products to the mining industry. Their customers require fast order fulfillment lead times, which are met by manufacturing products as quickly as possible within their 12 core manufacturing plants.
42Q Enables Production Readiness to Double the Volume at Comet’s Penang Facility
Comet’s facility in Penang, Malaysia needed to double the production volume of matching networks within a period of six months. While the manufacturing process itself could support the increase, the manual data collection process had reached the limits of its capability. The company needed to increase efficiency, improve quality, enhance traceability and wanted a single source of truth for all manufacturing data. They decided to implement a Manufacturing Execution System (MES) and eliminate all spreadsheet and paper based processes. They also wanted the system to seamlessly integrate with their ERP system and a variety of manufacturing equipment.
Cloud MES Supports Sophisticated Automation in a High Speed, Highly-Regulated Manufacturing Environment
A global medical device manufacturer had been producing complex Class II medical devices for years, using 42Q as their MES. Now they faced the challenge of manufacturing high-volume Class III medical devices with complex, fully automated production lines. They feared that implementing advanced, high-volume automation using 42Q MES would require significant factory downtime. The new production lines required a high level of sophisticated automation and a manufacturing execution system that supported and seamlessly integrated with such systems.
Digital Factory Transformation with 35,000 Pieces of Manufacturing Equipment Connected in the Cloud
Sanmina manufactures 250 million products per year. More of a challenge is that there are over 200,000 different top-level assemblies produced each year for 700 different OEM customers with up to 20,000 forecast changes per week. The OEMs operate in diverse industries including telecommunications, enterprise computing & storage, industrial and clean technology. A significant amount of production is for medical, aerospace and automotive products with strict regulatory requirements. The existing on-premise MES required significant maintenance and upgrade effort from the IT and operations teams. It was also limited in its ability to manage supply chains beyond the walls of each factory, and was not well suited for factory automation and other IIoT initiatives.
Values & Capabilities
Delivered by Manufacturing Experts
Cloud-Based Technology
Subscription-Based Pricing
Rapid Implementation
Flexible Configuration
Multi-Plant Visibility
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