Description
For Intel’s complex factory environments, quickly identifying tools that are operating below their optimal capacity and finding the root cause is crucial for maximizing production output. With thousands of tools involved in production and each manufacturing tool running from one to 50 operations, there are tens of thousands of tools and operations to monitor, analyze and adjust. Knowing where to focus engineering efforts is a monumental challenge.
To address this challenge, Intel IT collaborated with Virtual Factory (VF) experts to rapidly build and implement a new, robust diagnostic tool to analyze operational input and output from every factory machine. The tool delivers timely, meaningful data to help managers and engineers quickly and intuitively identify manufacturing tools with available capacity that are running below MOR and make the appropriate improvements.
This flexible and scalable solution delivers results in a simple grid modeled after the actual factory organization. It compares the data for current tool availability with that tool’s MOR availability and calculates a summary of statistics to guide the user toward areas of need. The team worked with the Technology Development Group to gain authorization and display equipment MOR data in the existing factory data analytics platform, called Data On The Spot (DOTS). Building on an existing analytics platform and collaborating across teams allowed the creation of the new analytics solution and ultimately led to data-driven breakthroughs.
Because all Intel factories follow a similar hierarchy, this new tool can be used in every facility to display a summary row of production areas. The information includes straightforward statistics that help describe the overall health of each area. As a result, areas in a factory that need attention can be identified within seconds. The data features of the tool also allow users to drill down for additional information with a few clicks.
The team built upon an existing platform to create and implement this new data analysis within 48 hours of the initial request. The solution rapidly increased production at one of Intel’s factories, generating significant value in the first quarter of usage.
Some unique attributes of our solution include the following:
- The analysis uses an easily traversable grid modeled after actual factory organization to allow fast and intuitive interactions.
- Areas in a factory that need help can be identified in seconds.
- Clearly presented, detailed analyses help find root causes of process behaviors.
- Copy Exactly! helps ensure rapid adoption across all of Intel’s facilities while providing self-service flexibility to fit each factory’s unique needs.
Intel IT is committed to making all of Intel’s manufacturing processes as efficient and productive as possible. Our accelerated analytics framework and value‑focused development teams are critical for meeting this commitment with maximum speed and effectiveness of the solutions that we develop. The MOR availability analysis tool is a good example of how this structure benefits the development of tools that improve manufacturing productivity and provide business value.