Case Studies
Case Study: Low Production Yields
This customer suffered from only 40% yield on the first battery of quality tests. Rework of very expensive technologies were hampering their ability to produce. We helped them get to 100% yield and double their production capacity in the process. They got an award from the Army.
| Company | Aerojet, Defense Contractor |
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| Product | SADARM (Sense and Destroy ARMor) |
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| Location | Los Angeles, CA |
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| Situation | Product assembled from 3 main subassemblies where characteristics interact. A few "tunable parameters" can be made at time of assembly, but had to be determined before assembly. Product first test pass rate was only 40% due to highly complex product, resulting in a staggering 60% product rework. |
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| Objective | Increase first test pass rate and reduce rework. Rework limiting ability to meet demand. |
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| Method | Searched for optimal combination of subassemblies such that all assemblies produced would maximize conformance to eventually 57 product specifications. Determined values for tunable parameters based on resulting proposed assembly. Upon each optimization run for given bins of subassemblies, a production assembly recommendations report was created listing matched subassemblies and tuning parameters to use. |
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| Result | Increased first test pass rate to 100%, rework approached zero. Capacity and ability to meet demand increased significantly |
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| Reference Available? | Yes |
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