FORCAM > Case Studies > Deliver Results in Productivity. C.s. YAP Engineering

Deliver Results in Productivity. C.s. YAP Engineering

Customer Company Size

Mid-size Company

Region

Asia

Country

Malaysia

Product

FORCAM FORCE
Data Collection Units (DCU)
Product Data Management (PDM)

Tech Stack

Data Mining
Data Visualization
Real-Time Data Collection

Implementation Scale

Enterprise-wide Deployment

Impact Metrics

Productivity Improvements
Cost Savings

Technology Category

Analytics & Modeling - Real Time Analytics
Application Infrastructure & Middleware - Data Exchange & Integration

Applicable Industries

Metals

Applicable Functions

Discrete Manufacturing
Quality Assurance

Use Cases

Predictive Maintenance
Factory Operations Visibility & Intelligence

Services

Data Science Services
System Integration

About The Customer

C.S.YAP Group of Companies were established in 1976. Since then, C.S.YAP investment in machinery has exceeded 20 million Ringgit Malaysia. Over the years, C.S.YAP has become a market leader of metal parts to different kinds of industries in Malaysia. With over 30 years of proven track records, the experience and knowhow of management and staff, coupled with a well-equipped plant. The company prides itself with a special quality process and certification alongside shop floor management technology from FORCAM to help create high quality durable goods that are manufactured with highest attention to detail and craftsmanship. The goal is to eliminate problems with mass produced products and responsibly manage resources and waste. C.S.YAP’s goal is to become a world class solution provider from concept to completion of metal products through continuous investment in latest technologies and best metal fabrication services. Revenue target is US $40 million by 2020.

The Challenge

C.S.YAP Group of Companies, a market leader of metal parts to different industries in Malaysia, faced significant challenges in their manufacturing process. The process was complex and could be impacted by many factors such as supplies, equipment, factory overhead, the need for special parts, and the people who work at all points in the process. The more variables there were, the greater the possibility of disruption to the smooth operations of the factory. Management styles and workforce could also have an impact on this process. For instance, human insight into a manufacturing process leading to more labor-efficient and cost-effective methods of production could affect the manufacturing process in a positive way. Not only did the operator need to understand the basic machining operations, correct tool usage, and correct speed of operation but also detect tool wear and replacement patterns. Skilled machinists usually made these decisions based on experience with no written instructions other than a blueprint of the designed part. Often this involved setting up the machine tool, running a few pieces through to test the arrangement, and then adjusting the setup until an acceptable part was produced. This could be a time-consuming and a tedious process.

The Solution

C.S.YAP implemented a two-phase project with FORCAM's technology. In the first phase, they focused on Product Data Management & Digital Numeric Control (PDM-DNC). They used FORCAM FORCE to collect, analyze, and make decisions based on data. Data was stored in a central data warehouse and could be entered, accessed, and extracted remotely. Data was also preprocessed, transformed, modeled, analyzed, interpreted, and evaluated using a combination of techniques. This phase enabled C.S.YAP to spread product data into the entire Product Lifecycle Management (PLM) launch-process, in order to produce complex products. This significantly enhanced the effectiveness of the launch process and lowered the risk of human error during order data transfer. In the second phase, C.S.YAP moved forward to include real-time machine data collection, web visualization, and alerting. This implementation helped the workforce to utilize data generated through FORCAM FORCE to further scrutinize and increase shop floor efficiency.

Operational Impact

C.S.YAP was able to minimize risk related issues with transferring production data to its NC assets within the first phase of project deployment.
In following stages the company could create its own transparent factory and leap into a more informed production process.
The company is now able to meaningfully track and manage all changes to product related data and spend less time organizing and tracking design data by reusing the data sets.
They also managed to install a special rewards program for its workforce, which not only encourages the empowerment of operators but also enhances organizational excellence with the result of an increase in market competitiveness.

Quantitative Benefit