"We lowered our manufacturing costs by 20%, reduced returns by 40% and slashed repair costs by $5 million over the past 4 years.” — Director of Quality, Force10 Networks

Reduce Your Cost of Goods Sold

SigmaSure Manufacturing & Test Insight provides you with real-time manufacturing process intelligence across your supply chain. Inadequate product test procedures, low yields and excess rework all continuously increase your cost of goods sold (COGS). SigmaSure Manufacturing & Test Insight empowers you to take back control of your manufacturing process and dramatically reduce COGS.

The SigmaSure Advantage

SigmaSure Manufacturing & Test Insight enables you to:

Contain Unexpected Manufacturing Costs by quickly reacting to out-of-compliance manufacturing process shifts and other events exposed via SigmaSure’s dash-board and alerts.		Drive Down Supplier Costs by monitoring in-process test data across all your component suppliers, manufacturing sites and service centers.
Accelerate New Product Introductions by rolling up and analyzing granular parametric and attribute test data associated with each serial number and subassem-bly.		Optimize Resources by automatically collecting data from the test floor, and redirecting your engineering team away from time-consuming data gathering tasks to high-value problem solving.
Increase Yields and Minimize Rework and Returns by proactively leveraging manufacturing and test data that is easily accessible via a Web browser anywhere in the world.		Reduce Risk by joining more than 150 worldwide installations that rely on SigmaSure to produce high-yield technologies including avionics, medical devices, photo voltaic, power supplies, routers, smart phones, and wireless headsets.

SigmaSure Features

SigmaSure Manufacturing & Test Insight offers the following essential features:

Machine-to-Machine Parametric Data Gathering APIs deliver high data accuracy and granularity. Standard ATE interfaces include: Agilent/HP, AOI, Flying Probe, ICT, CAMx IPC-2547, NI LabVIEW, TestStand, VEE, and X-ray. BOM (Bill of Material) data is extracted directly from PLM. Sigma-Sure supports other enterprise applications such as ERP, MES and CRM through a standard application programming interface (API).

Advanced Statistical Process Control (SPC) Reports including USL, LSL, UCL, LCL, Average, Sigma, Skewness, Kurtosis, Cp, Cpk, Max, Min, etc.

Easy-to-Use KPI Dashboard and Reporting allow better management of production flow. Dashboard options include first pass yield, top product failures, top failed test, top station pass fail, top defect codes, top repair codes, top failed components, bone pile cost, marginal test mea-surements and operator variation. SigmaSure’s Best Practice Wizard automates dashboard creation, replaying your spe-cified drill-down discovery process.

Integration with SigmaSure Supplier Quality and RMA and Warranty Solutions
captures a full 360 degree lifecycle history for any serialized or lot-based product.

Typical Work Flow

SigmaSure supports industry standard ATE interfaces.

SigmaSure Manufacturing & Test Insight is accessible via any Web browser, enabling you to easily monitor test stations, manage data collection and view real-time test results across multiple sites from your desktop.

First, SigmaSure’s SigmaProbe captures test and parametric data test from your ATE, operator-filled forms and batch interfaces. SigmaSure automatically collects, aggregates and synchronizes this data with other SigmaSure Servers across your global network.

During new product introduction, you select the data you want to view, as well as data update frequency.

For steady state production monitoring, you can customize dashboards to present your KPIs on a real-time basis, and SigmaSure alerts notify you any time your manufacturing process goes out of compliance.

SigmaSure provides advanced analytics and Statistical Process Control (SPC) reports – including USL, LSL, UCL, LCL, Average, Sigma, Skewness, Kurtosis, Cp, Cpk, Max, Min, etc. – enabling you to analyze data and maintain a high-yield process. In addition, by using SigmaSure’s Discovery Wizards, you can capture and automate frequent drill-down analysis sequences.

Optional Modules

Alerts Module SigmaSure Alerts allow you to manage your manufacturing process by exception. Alerting can be configured for changes in yields and data gathering stoppages, and personnel on notification lists can be designated per time of day and severity – warning, critical and fatal. SigmaSure Alerts are delivered via Web, email, SMS and iPhone’s SigmaAlerts. Automated Maverick Analysis Module Automated Maverick Analysis enables you to quickly identify which products meet the highest performance criteria and which products exhibit anomalistic characteristics. The module provides median/mean performance deviation metrics on parameters such as voltage, frequency, current and resistance for complex devices including ASICs, PCBs, batteries and power supplies. SigmaSure conforms to the Joint Electron Device Engineering Council’s EIA/JESD 50 standard. Genealogy Module The SigmaSure Genealogy Module captures the hierarchy of parts on serial numbered or lot-based products and subas-semblies. Historical assembly (date codes, batch numbers) and test parametric data are captured by instance serial num-ber. With the Genealogy Module, you can drill down and drill up on the part assembly hierarchy as well as history to pin-point the root cause of low yield or high return products, such as specific part, supplier, operator, station and test mea-surement. Process Flow Visualization Module SigmaQuest’s patent pending Process Flow Visualization enables you to quickly observe and track all product develop-ment phases via an intuitive, process flow graph. You can quickly determine if your manufacturing processes are in com-pliance as specified. For example, you can identify skipped tests. Process flow visualization aids in monitoring process compliance.

SigmaQuest alerts can now be sent automatically to your iPhone. Example of Automated Maverick Analysis.