unleashing operational excellence in manufacturing rob rudder executive vice president camstar...
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Unleashing Operational Excellence in Manufacturing
Rob Rudder
Executive Vice President
Camstar Systems
©2007 Camstar Systems. All rights reserved. CONFIDENTIAL 22
Camstar Overview
Company At A Glance Privately Held Founded 1984 (targeting Hi-tech)
Offices USA: HQ, Charlotte, NC
San Jose, CA
Tampa, FL Asia: Shanghai, China
Singapore
Industries Medical Device and Diagnostics Biotech Semiconductor Solar Electronics Assembly Storage
Customers
450+ Manufacturing sites
75% are tier 1 > $1 Billion
90% are using Microsoft “Front Office”
80% are using Oracle or SAP for ERP
Customer “Snap Shot”
©2007 Camstar Systems. All rights reserved. CONFIDENTIAL 3
High Tech Market Segmentation
Electronics AssemblyStorage
Semiconductor Solar Storage
El
Electronics
©2007 Camstar Systems. All rights reserved. CONFIDENTIAL 4
High Tech Market Segmentation
Electronics AssemblyStorage
Semiconductor Solar Storage
El
Electronics
• Wafer Bump
• Wafer Test
• Wafer Back grind
• Die Preparation
• Assembly
• Module Test
• Packaging
Manufacturing Process
©2007 Camstar Systems. All rights reserved. CONFIDENTIAL 5
The Challenge to Operational Excellence
Plant
Efficiency
Productivity
MES
Enterprise
Proactive
Quality
Integration w/
Business Sys.
Plant to
Plant Flows
Visibility into
Production
Mfg Ops
Efficiency
Productivity
MES
Operational Challenges:
Speed of Innovation
Complexity of Products & Value Chain
Quality Expectations
Cost Pressures
Enterprise Manufacturing and Quality Systems providing operations-wide control, efficiency and
intelligence.
©2007 Camstar Systems. All rights reserved. CONFIDENTIAL 6
The Paradigm Shift
Enterprise Manufacturing and Quality Systems providing operations-wide control, efficiency and
intelligence.
Manufacturing
360
360
Collaboration360
Coordination
360
Visibility
360
Compliance
360
Control
People Ready
Process Empowered
Platform Enabled
©2007 Camstar Systems. All rights reserved. CONFIDENTIAL 7
Business Transformation
Transform
Your OperationsProduct Quality
and Risk
Manufacturing
Agility
Time to
Volume
Low Cost
Manufacturing
& Quality
Automatically
enforce processes
Electronic
manufacturing
audit trail
Integrated root
cause analysis
Quick process
configuration
Flexible, small lots
Customize complex
products
Remove all paper
Efficient process
change management
Synchronize
process/product
design to
manufacturing
Lean operations
Auto release
electronic Travelers
Improve yield
and cycle time
Industry Best Practices
Enterprise Manufacturing and Quality Platform
Transform Your
Operations
Provides agility and control to maximize your revenue,
minimize risk exposure and achieve operational excellence.
Enterprise Manufacturing and Quality Systems providing operations-wide control, efficiency and
intelligence.
F I N I S A R C O R P O R A T I O N
Unleashing Operational Excellence in Manufacturing
Unleashing Operational Excellence in Manufacturing
Giri Chodavarapu
Director of Business Applications
Finisar Corporation, Sunnyvale, CA
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Finisar At A Glance
A market leader
Broad product offering of fiber optic
transceivers/transponders and components
Experts in Fiber Channel test and monitoring
systems
Focused on high-speed data communications
Local Area Networks (LANs)
Storage Area Networks (SANs)
Metropolitan Area Networks (MANs)
High-speed serial protocols
Powered by a sustainable business model
Vertical integration
Internal off-shore manufacturing capabilities
Annual Revenue: $419.2M – FY2007
Our Customers: Majority of LAN, SAN & Telecom
Equipment Manufacturers, such as, 3COM, Brocade,
Cisco, Dell, IBM, HP, Intel, Juniper, Lucent, Nortel, and
many others
SAN/LAN/MAN Optical Transceivers
Network Test and Monitoring
10
Industry Growth Drivers: Bandwidth Demand
The Digital HomeBroad-band internet access (100M), video (IP TV), POTS
Multiple set-top boxes per household
Applications and content delivery (On-line gaming, Video on Demand, telecommuting, net meetings etc.)30 minutes of video = 1 year of emails
Global IP TV and IP Video
Broadband penetration estimated at 18% in U.S. (35% in
Europe) and growing to 29% by 2009 in U.S. (51% in Europe)
HDTV
Increases bandwidth demand up
by a factor of 5-10x over standard
video
Video over wireless
networks
3G wireless
Explosion in number of people able to afford
wireless service (from 2 billion subscribers today
to 4 billion in 2010)
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R&D Investments
Vertical Integration: The Critical Steps
May 2001 March 2003 April 2004 Jan 2005
Low-cost off-
shore
production
(Ipoh,
Malaysia)
Genoa
acquisition
Honeywell
VCSEL
acquisition
Infineon
transceiver
and
transponder
acquisition
Step 1 Step 2 Step 3 Step 4
FY 2006-
2007
Integrate
the pieces
Step 5
Our MES Vision
ERP
Enterprise WIP SYS
SCM
InSite
Event track
• Lot Tracking
• Equip. Tracking
• Defect Reason
SQL
Reporting
Services
Production Control
IDS
MES
Traceability
Design
Information
Manufacturing
Data Collection
PDA
PC
Operator I/F
Equipment Management
QC & QA
Interface System
Failure Control
Input OutputWIP
Functions
• Paper less
• Prevention simple
mistake
Corporate
Wide
Corporate
Wide
Each FactoryEach Factory
Time to volume Improve time-to-market of new products by making the transition from
engineering through NPI process into volume production in one facility under a common process owner;
Cycle time Improve cycle time to ensure that critical inventory reaches customers when
they want to receive our products;
Flexibility / Agility Provide capacity that can be adjusted to respond to demand fluctuations at
the lowest possible cost configurations while maintaining short cycle time and meeting lowest possible cost targets;
Provide “on demand” assembly resulting in frequent changes
MES Business Requirements
MES Business Requirements
Quality Fully Computerized Manufacturing Data Management Material and Equipment Quality Data Traceability Automated Operator Instruction Automated Test/Inspection Instruction Real-time SPC
Speed (Flexibility) Shorter “Turn Around Time” and On-time “Delivery” Faster New Product Introduction Quicker Quality Feedback
IT Requirements
1. MES system should handle over 4mil txn per day;
2. Integrates with AD (Active Directory)
3. Better architecture in terms of scalability;
4. Able to meet our deployment timeline;
5. Customizations might not be as extensive (and it is easierto find .Net developers than C++ developers);
6. XML technology, open and adaptable;
7. Cost of Ownership 1 Business Analyst per site 1 Corporate Report Writer managing all plants
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Insite 4.1 Benchmark Results Benchmark Environment:The Benchmark work is performed at Microsoft
technology centre, Mountain view. Hardware:
(4) HP DL360 Application Servers (4) HP DL380 Application Servers (4) HP DL580 Application Servers (4) Windows XP Pro Clients
Storage: DB servers attached to a Hitachi SAN (8TB
usable)
Application Servers: Windows Server 2003 Camstar Insite 4.1 with hotfix 71
Clients: Camstar XML client C# application test client with 8 background
workers
* Data store replication enabled, 100GB Database
Conclusion: Insite 4.1 running on SQL Server 2005 could handle 3x of our existing transaction volume
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MES Rollout
Fremont Facility Initial Implementation – 2001 (prior to Finisar acquisition) Upgraded to Insite 3.4 – 04/2006
Sunnyvale Facility Initial Implementation (insite 3.2, SQLServer 2000) – 12/2003 Upgraded to Insite 4.1 scheduled for 04/2008
Ipoh Facility Initial Implementation (insite 3.2, SQLServer 2000) – 12/2003 Current txn volume – 2mil txn/day (projected to be 4mil txn/day by 2010) Current Database size – 2.4 TB (growing 25GB per week) Upgrade to Insite 4.1, SQL Server 2005 scheduled for 04/2008
Allen, TX Facility Phase 1 – Epi Line (all lots started after 8/2 now tracked in Camstar.
Camstar interface to replace Oracle tracking 3rd week of August) Phase 2 – Rest of the FAB (scheduled for 12/2007)
Key Benefits
Improved the yield by having better control over the throughput and curbing the losses on the production floor.
Improved reliability and failure analysis by having the broad vision on the critical test operations parameter.
Improved resource management by tracking the resource performance and ability to identify the issues related to the resources, which results into deliver the better quality product.
Improved cycle time by identifying the bottlenecks on the process workflows.
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19
Operational Excellence Award
200,000 ft2 clean room
Cisco Operational Excellence Award
Ipoh, MalaysiaAcquired 200120 acres of land640,000 ft2 facility
Finisar is one of select few optics companies to own assembly / mfg facilities
2005 Supplier Award
For Excellence