Customer Succes Stories

 

 

Astronics Advanced Electronic Systems
Leading Manufacturer of Commercial and Military Aerospace Platforms RealizesCost Savings by Preventing Late-stage Rework
Industry

Aerospace/Defense - Commercial and Military Aerospace Platforms

 

Overview

Like many electronics manufacturers, Astronics AES was challenged with its manual product development processes. The company produces well over 100 products, each with their own processes and workflows, and over 20,000 parts. To position themselves for continued growth and meet the demands of its aerospace customers (Boeing, Panasonic, Avionics, AirBus, among others) for high quality products, the executive team was motivated to look at new strategies that would maintain the company's competitive edge and product reputation in bringing leading electrical power to passengers and airline personnel. Investing in a Product Lifecycle Management (PLM) system to tighten product lifecycle processes and ensure that accurate product data was shared among design and manufacturing teams was the first step.

 

The company required a PLM system that provided easy integration with their ERP environment, Intuitive ERP, so that product data such as Bill of Materials (BOMs), drawings and changes could be automatically ported to the Intuitive system and eliminate errors related to hand-entering data. They also wanted the ability to integrate the PLM system with their engineering design environments, SolidWorks and Cadence® OrCAD® CIS.

 

"We evaluated a number of PLM systems for the purpose of creating a best practices environment and found Omnify's PLM software stood out from the crowd of PLM vendors in terms of it being a robust system, having a seamless interface to our Intuitive ERP and extremely good people standing behind the Omnify product."

 

Return on Investment
  • Eliminate potential data inaccuracies and costly rework
  • Reduce searching time with data in a single location
  • Standardize and control internal processes
  • Ensure accuracy of data across the enterprise
  • Facilitate meeting ISO and FAA regulatory requirements

 

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Athena Technologies

Athena Technologies Cuts Product Development Cycles and Meets Market Windows for Flight Control Technologies

Industry

Aerospace/Defense - Navigation and Control Systems

 

Overview

Challenged by the seemingly limitless opportunity for growth and the need to position its manufacturing operations to meet that challenge, Athena set out to find a Product Lifecycle Management (PLM) solution that could stand up to its most demanding requirements. Critical focus was placed on not only ease of use and cost of operation, but also how quickly and "how painlessly" the company could minimize the downtime of new product delivery while the PLM solution was being implemented.

 

Athena looked at several vendors before choosing a PLM solution from Omnify Software. They chose Omnify due to its ability to deploy quickly and provide an easy to use solution built on an open technology platform with direct interfaces to engineering tools and manufacturing systems. The ease of implementation with the Omnify solution allowed Athena to continue shipping new product concurrently.

 

Return on Investment
  • Decreased product development cycles
  • Able to meet time-to-market windows
  • Proactively catch errors/improved data integrity
  • Enhanced communication with vendors
  • Reliable engineering change processes

 

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Avid

Design and Manufacturing Integration Eliminates Duplicate Database Data Entry, Shortens ECO Processes and Improves Supplier Communication

Industry

Digital Audio and Video Technology

 

Overview

Operating 24 hours a day, 7 days a week with worldwide partners and suppliers, Avid needed to create a unified environment for their global product development teams to easily find and share product information in real-time. The company was managing product data in multiple systems that did not interface with each other. This environment resulted in the duplicate entry of data into various systems.

 

The company set out to find a Product Lifecycle Management (PLM) system in order to help streamline their product design and development processes for Avid video products. “Our ultimate goal was to create a central location for data and knowledge sharing throughout the evolution of a product.”

 

After researching six PLM vendors over a five-month period, Avid selected the Omnify Empower PLM solution. Implementing Omnify has allowed the Avid Video business unit to meet their goal of creating a central repository for product information. All of Avid’s various systems, including their ISO (International Standards Organization), ECO (Engineering Change Order) and Test Procedures have been consolidated into one database.

 

A direct link from the Omnify Empower database to Mentor Graphics DxDatabook™ allows engineers to select parts and access all part data such as symbols, device name, component package, and documentation from Omnify without leaving their design environment. Duplicate data entry has been eliminated through bi-directional sharing of information between the Omnify Empower PLM system and SAP.

 

Return on Investment

• Improved data integrity

• Improved resource allocation

• Ensure new products are built to the latest revision

• Real-time access to information for global suppliers

• Accelerate ECO and new product processes

• Cost-effectively scale to accommodate new users

 

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Crystal Technology, Inc.

Manufacturer of Oxide Single Crystals Reduces Engineering Change Cycles by 16% and Achieves $250,000 in Cost Savings

Industry

Manufacturer of Oxide Single Crystals

 

Overview

Volume manufacturing is Crystal’s specialty with a notable annual production of 60 tons of single-crystalline lithium niobate. Crystal’s staff of 150 people delivers a number of highly customized product lines involving internal and external development teams. This environment, coupled with increasing pressure from customers for solutions to be delivered in a much faster timeframe, required Crystal to take a look at their existing product development processes and find ways to improve efficiencies.

 

Automating their manual processes was essential to streamline communication among the product development teams for faster reviews and evaluation. In addition, automating the sharing of product development and change management information between their Infor ERP Baan system and Cadence® OrCAD® CIS design environment would address data inconsistencies and eliminate re-work.

 

After assessing PLM vendors, Crystal selected the Omnify PLM solution because of its ability to address all of their requirements at a much more reasonable cost, easily integrate with their existing design and manufacturing systems, and the willingness of the Omnify team to support their needs.

 

Return on Investment

  • Reduced ECO cycle time by 16%
  • Estimated overall savings of $250k over 5 years
  • Ensures accuracy of data across the enterprise
  • Easy to use solution/fast user adoption
  • Eliminate waste in manually searching and accessing product information
  • Meet ISO and RoHS compliance requirements

 

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CVG-Avtec

Easier and Efficient BOM Revision Management for Design of Complex Data Communications Products

Industry

SATCOM and Communications

 

Overview

For almost three decades, CVG, Inc. and Avtec Systems, Inc. (CVG-Avtec), a Kratos Company, has offered systems engineering services to the aerospace and defense industries, providing innovative custom hardware, software, algorithms, simulations and analyses to solve its customers' toughest real-world engineering problems.

 

As a leading provider of advanced communications systems, CVG-Avtec generates a large volume of complex engineering products. This environment inevitably results in a high quantity of engineering changes. CVG-Avtec needed a way to accurately track all of the Bill of Material (BOM) changes and have the ability to view previous revisions with a clear history of the product’s lifecycle.

 

The company initially tried to track and manage their engineering change/revision process with Excel spreadsheets. Managing detailed change information in this manor did not provide the security or history tracking that CVG-Avtec needed to effectively manage product revisions and the manual entry of information was highly susceptible to data inaccuracies. The company also tried using their existing ERP (Enterprise Resource Planning) system to manage revisions. Tracking different revisions of the same BOM in their ERP system proved to be time-consuming and tedious, requiring the creation of a different BOM part number for each revision which did not have any relation to each other.

 

All of CVG-Avtec’s product data is now centralized and managed within Empower PLM. The company met its primary goal of eliminating the tedious task of managing BOM information within their ERP system. With features such as complete BOM revision control, audit trails, BOM comparisons and full BOM hierarchy views, Empower PLM makes CVG-Avtec’s BOM management process much easier and more efficient. All BOM revisions now exist solely in the Empower PLM system with only the current released BOM residing in ERP.

 

Return on Investment

  • Eliminate tedious revision management in ERP (70% time savings creating, tracking, updating)
  • 95% reduction in time spent searching for data with centralized product record
  • 100% improved data accuracy through automated processes
  • Traceability on all engineering changes
  • More efficient and effective configuration management
  • Guarantee manufacturing is building to the correct BOM
  • Clear view of product’s lifecycle

 

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Cynosure

Medical Device Manufacturer Streamlines Product Design and Manufacturing Processes and Shortens New Product Development Timelines for Light-based Aesthetic and Medical Treatment Systems

Industry

Medical Device - Light-based Aesthetic Treatment Systems

 

Overview

Cynosure was looking to streamline their product design and manufacturing processes in order to shorten new product development timelines and ease collaboration with suppliers. They needed to implement technology that provided a centralized location to store product documentation such as bill of materials (BOMs) and design drawings, in addition to automate the processing of engineering change orders (ECOs). Cynosure wanted the ability to import SolidWorks software files and OrCAD BOMs in addition to the ability to upload data to both their existing and future ERP systems. Easy export of information into common formats such as Excel spreadsheets and BOM comparison functionality were important features. Enabling secure access to product information for key suppliers and contract manufacturers were also fundamental requirements.

 

Cynosure selected Omnify Software due to Omnify's ease of use, powerful data sharing capabilities, and affordable cost. Omnify's unique ability to directly integrate with SolidWorks and Cadence® OrCAD® Capture CIS have helped to greatly decrease the time required for documenting change as well as significantly increase the quality and accuracy of product data.

 

Return on Investment
  • Data validation and error checking earlier in the design cycle
  • Decreased engineering change cycles through direct integration with their engineering tools
  • Improved data integrity
  • Decreased time spent searching for information
  • Reduced product redundancies
  • Shortened product development time
  • Shortened time-to-market
  • Quick implementation
  • Easy to use

 

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Edge Products

Premier Manufacturer of Modules and Programmers for Major Vehicle Manufacturers Tightens Change Control Processes and Cuts Product Return Rates by Over 50%

Industry

Automotive - Modules and Programmers for Major Vehicle Manufacturers

 

Overview

Edge Products experienced some changes in management that brought in new personnel with vast industry experience. The new team identified a need for improved change and part control processes. Edge is a rapidly growing company and the nature of their products requires fast development cycles. For example, if a vehicle manufacturer makes a change to an existing product, Edge must react quickly, often with a change to their products.

 

Edge's manual engineering processes were not conducive to this constantly changing product design environment. The company wanted to implement electronic processes for easy access to product information and improved efficiency. Edge had an ERP system in place which contained parts and order information but lacked the type of functionality required to manage detailed engineering data, particularly engineering changes.

 

Edge was looking for a Product Lifecycle Management (PLM) system to remove the paperwork burden and provide a complete documentation trail. They searched specifically for a system that included engineering change, Bill of Material (BOM) and documentation management. Direct integration with their existing ERP system, Sage MAS 200 ERP, was a necessity.

 

Return on Investment

  • Over a 50% reduction in product return rates
  • Improved product quality
  • Reduced costly rework
  • Standardized and organized internal processes
  • Improved and streamlined communication
  • Ensure accuracy of data across the enterprise
  • Easily share data with internal and external teams

 

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Grass Valley

Leader in Video Technology Updates Legacy Systems to Gain Automated and Integrated Product Development Processes


Industry

Video Technology

 

Overview

For more than 50 years, the Grass Valley™ name has been synonymous with innovation, leadership, and performance. As the premiere video technology solutions company, Grass Valley knows what it takes to keep up with the fast pace of technology advancements, customer requirements and a global workforce. With an aging component database and a Product Data Management (PDM) system that eventually was announced End of Life (EOL) the company had to find a new way to support their complex product lifecycle requirements. Grass Valley needed a next generation solution to automate engineering change and Bill of Material (BOM) management as well as streamline their engineering and manufacturing processes.

 

A team comprised of Engineering and IT staff set out to find the ideal Product Lifecycle Management solution. “Besides the functional requirements, our main goals were to find an off- the-shelf solution that did not require customizations, was easy to use and offered a good price to performance ratio,” stated Gerard Meijer, Manager of Digital Hardware and Layout for Grass Valley. “A few additional PLM requirements included out-of-the -box integration with our existing CAD tools from Mentor Graphics, bi-directional integration with our manufacturing systems and an internally developed engineering database, plus an easy to use and browser independent interface for the manufacturing floor. All possible solutions were compared on a score card and Omnify Empower PLM was the best possible solution for us.”

 

Grass Valley now has highly automated and integrated processes for ECR’s (Engineering Change Requests) and CQ’s (Component Qualifications). Empower PLM provides Grass Valley with the ability to easily search for information, view a complete hierarchical BOM list, and deliver automatic notifications on changes. The company is able to share pertinent development information across their entire enterprise by integrating Design, Manufacturing and the factory floor via Empower PLM. In addition, Grass Valley has opened the Empower PLM system to their Contract Manufacturer (CM). Their CM has full yet controlled access to product documentation, BOMs, and ECOs and is included in the automated process flows.

 

Return on Investment

  • Easy transition from aging legacy systems
  • Efficient electronic BOM and change management
  • Easy to use, flexible and cost effective solution
  • Integration with Mentor Graphics engineering design tools
  • Integration with their business and manufacturing systems
  • Secure access to product information for their contract manufacturer
  • Collaboration among design, manufacturing, factory and partners
  • Shorter component qualification and engineering change request lead time

 

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Intelligent Manufacturing Solutions

Electronics Manufacturing Services Provider Improves Documentation Communication with Customers by 100%

Industry

Electronics Manufacturing Services Provider

 

Overview

Intelligent Manufacturing Solutions (IMS) is a full service Electronics Manufacturing Services (EMS) provider, specializing in New Product Introduction and Quick Turn Assembly, from Prototype through Moderate Run Production. IMS provides "Intelligent Solutions" to a diversified customer base. These solutions include Quick Turn Prototyping, Sourcing Services, Supply Chain Stabilization Programs, Enhanced Manufacturability Guidance, Test Design and Development, and Safe Passage Transition.

 

With competitive pressures locally and offshore, IMS needed to increase their value-add to provide the highest level of service to their customers. IMS recognized that Omnify's PLM system could facilitate this by providing a single environment for creating and changing product information and enabling vital product data to be easily shared between IMS and their customers.

 

Return on Investment
  • 100% reduction in ECO notification time
  • 100% improvement in documentation communication
  • Improved and streamlined communication
  • Compare BOMs in minutes vs. hours
  • Elimination of scrap due to incorrect builds
  • Elimination of lost schedule time due to supply or BOM issues
  • Single location to create and change product data
  • IMS involved in sourcing and design decisions

 

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L3 Klein Associates, Inc.

Automated Processes Help L3 Klein Associates Decrease Inventory Exercises by 50%

 

Industry

Side Scan Sonar Systems

 

Overview

L3 Klein was searching for a Product Lifecycle Management (PLM) solution that would enable greater visibility into their entire development cycle, from idea and request for materials, to engineering and manufacturing. The solution would replace L3 Klein's homegrown solution that relied heavily on Excel spreadsheets, e-mail and manual requests that resulted in inefficiencies in the development process. The PLM solution would also have to integrate seamlessly with L3 Klein's existing ERP system, VISUAL Enterprise as well as their engineering design environment, Cadence® OrCAD® Capture CIS.

 

Omnify met all of L3 Klein's requirements for functionality, cost, ease-of-use, and unmatched customer support. Through Omnify, L3 Klein automated their time-consuming manual processes and established collaboration between engineering and manufacturing. L3 Klein now has visibility into their entire product development cycle. Data integrity, cycle times and product innovation have all improved since implementing Omnify.

 

Return on Investment
  • Inventory exercise time reduced by 50%
  • Eliminated delays in reporting and scheduling
  • Improved data integrity
  • Unsurpassed efficiency levels
  • Improved part selection process
  • Reduced product redundancies
  • Decreased time-to-market

 

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Microstrain, Inc.

Leader in Design and Manufacture of Smart Sensors Manages Extraordinary Growth Without Having to Increase Production Staff

Industry

Microminiature Sensors

 

Overview

When MicroStrain was first founded, it used an entry-level financial accounting system and managed scheduling and job costing on spreadsheets. Production managers walked around the shop collecting parts and checking them off of a paper bill of materials. This approach was very difficult to understand the demand for their products and the parts that were available to meet that demand. The company’s engineers stored their design information in various folders and it was often difficult to find the latest versions of PCB designs, mechanical designs, bill of materials (BOMs) and other critical information. The engineering change order (ECO) process was managed by passing around a paper form.

 

Microstrain decided to move to the Made2Manage ERP system. After it was completed, Consona announced an interface between Made2Manage ERP and the Omnify Software product lifecycle management (PLM) system. Microstrain saw the potential for further improvements by automating engineering change orders via Omnify PLM and integrating product development and production management processes.

 

The implementation of the Made2Manage ERP and Omnify PLM systems helped MicroStrain, Inc. manage extraordinary growth without having to increase administrative staff.

 

Return on Investment

  • Doubled annual revenue in the past two years without having to add production staff
  • Reduced turnaround time on the average order from one week to two days
  • Reduced inbound shipping charges by approximately 35 percent due to better material planning

 

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Pathway Medical Technologies

Pathway Medical Technologies Engineers More Products and Eases Audit Processes

Industry

Endovascular treatments for Peripheral Arterial Disease (PAD)

 

Overview

Pathway Medical Technologies was using a paper-based system for managing all of its product documentation, part drawings and engineering changes. The company utilized a room that housed all of the paper procedures and hard drawings with a checkout system similar to a library. The company wanted to bring in a PLM system to streamline the entire engineering change process, implement better security with document vaulting, improve Bill of Material (BOM) management, and make product information (drawings, blueprints, revisions, and supporting materials) easily yet securely accessible to appropriate team members.

 

Pathway selected the Empower PLM solution from Omnify Software because of its ease of use, fast deployment time and low cost. Document control, engineering change, BOM and regulatory conformance processes are now managed via the Empower PLM system. All departments that have governing procedures are using the system including: design engineering, quality, regulatory, manufacturing engineering, purchasing operations, and even facilities management. Any changes made to any procedures are performed and managed within Empower PLM.

 

As a medical device manufacturer, Empower PLM product features such as Quality Management, for documenting and tracking all non-conformances and customer complaints, and Training Management, to automate the management of all internal and external training, address the companies’ need to comply with ISO quality management system requirements.

Managing compliance data with Empower PLM has simplified Pathway's audit process, making it much easier to show auditors how product information is accessed and tracked online and prove the audit trail of activity for documentation as well as get requested documents much faster than through their previous paper-based vault system.

 

Return on Investment
  • Affordable, easy to use, quick to implement system for start-up
  • Ability to engineer more products with resource time-savings
  • Streamline entire engineering change process
  • Eliminate tedious paper-based, hard copy system
  • Centralized and secure product information
  • Ease ISO compliance audits/processes
  • Compliance with quality system requirements
  • Integration with Exact MAX ERP system
  • Single system for product data, quality and training management

 

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Petra Solar

Petra Solar Takes a Smart Approach to Product Development with PLM

Industry

Smart Energy Solutions

 

Overview

As a new company in a high-growth industry, Petra Solar needed to implement systems and processes to manage their large volume of engineering data. Growing from about sixty employees to over one hundred and fifty in a year (a vast majority in engineering), Petra Solarfound that their current environment for managing engineering activity needed to be more efficient and streamlined. The company’s processes were manual and all product related data was stored on secured drives.

 

Petra Solar wanted to become more mechanized with automated processes around document control, engineering changes, and Bill of Material (BOM) management. They also wanted to improve their processes related to meeting compliance in order to ensure the use of compliant parts early in the design cycle. With previous experience using Product Lifecycle Management (PLM), Petra Solar knew there was a need for a PLM system to be able to manage their complex engineering activity.

 

Petra Solar implemented the Omnify Empower PLM solution to address their product development needs. Empower PLM is now the primary tool used to develop and solidify all design changes and track a product’s lifecycle. With

Empower PLM in place, Petra Solar has replaced manual processes with a more disciplined and automated approach for part number creation, part development, BOM management, Engineering Change Orders (ECOs),

and document control.

 

Return on Investment

  • Estimated 74% reduction in ECO cycle time
  • Able to increase product volume
  • Affordable, scalable, easy to use PLM system for SMB
  • Eliminate replication of error-prone data
  • More easily meet utility compliance requirements

 

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PLC Medical Systems, Inc.

Leader in Innovative Technologies for the Cardiac and Vascular Markets Automates Engineering Change and Training Processes for Continuous Improvement and FDA/ISO Compliance

Industry

Medical Aesthetics

 

Overview

The company was managing product data with a homegrown system developed in an Access database that required a great deal of manual intervention and paper processes. If someone changed a Quality document they would have to print it out, pull out the old document from a folder, put in the new version and then walk around from person to person for sign-off. This setup did not have the necessary tracking for who was actually trained on a certain procedure, who signed off on an Engineering Change Order (ECO), or when items were signed-off. In addition, it did not allow PLC to capture employee product knowledge so if anyone left the company they took that knowledge with them.

 

PLC was looking to replace the homegrown database with a solution that would allow Documentation Control to keep ECOs moving through an automated system rather than a ‘walking system’ where they had to physically walk from person to person for sign-off. In addition, being in a highly regulated industry required PLC to set up more formal, automated processes.

 

Return on Investment

  • Meet stringent FDA and ISO compliance requirements
  • Improve ECO and Training process efficiencies
  • Substantial labor savings due to automated processes
  • Significant cut in change approval to production time

 

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Redline Communications

Redline Communications Achieves 100% Return on Investment from Omnify Software in First Year

Industry

Telecom - Advanced Broadband Wireless Access and Backhaul Solutions

 

Overview

Redline was searching for a PLM solution that would integrate all their Bill of Materials (BOMs), engineering changes/ECOs, and part data into a single repository that could be easily accessible by everyone involved in the product development process (internal teams, contract manufacturing, and offshore design partners).

 

A key requirement was that the PLM solution could easily integrate with their EDA design environment, Cadence® OrCAD® Capture CIS and was open and scalable enough to allow for future integrations with other applications such as their Financial and Purchasing systems.

 

Omnify provided Redline with a solution that fit their need for control over BOMs, ECOs, and Documentation in addition to meeting their integration demands.

 

Return on Investment

  • 100% return on investment in the first year
  • Shortened and streamlined communication cycles with internal and external teams
  • Decreased engineering change cycles
  • Assured data quality by eliminating human error
  • Reduced scrap and rework
  • Complete implementation deployed in days with no downtime

 

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Remec Broadband Wireless

Company Synchronizes Local and Remote Sites, Reducing Engineering Change Cycle by 46%

Industry

Telecom-Integrated Microwave and Millimeter Wave Subsystem Solutions

 

Overview

Remec Broadband Wireless was challenged with arduous paper processes that had to be replicated at two facilities-one in the United States and a manufacturing facility in the Philippines- which resulted in resource burdens and posed a high potential for user error. The company wanted to implement a system for paperless capture of Engineering Change Orders (ECOs) with online approvals and complete tracking of all changes as well as maintain links to CARs (Corrective Action Reports), FAIs (First Article of Inspection), and TDAs (Temporary Deviation Article), for any given part. A single repository for product documentation and controlled product revisions across remote sites was extremely important in order to get everyone in sync.

 

As a fast growing company, Remec Broadband Wireless looked for an affordable, scalable Product Lifecycle Management (PLM) solution that also integrated tightly with their existing Intuitive ERP environment in order to provide one common database that sent data to and from the ERP system.

 

Return on Investment

  • 46% reduction in Engineering Change Order (ECO) cycle time
  • Streamline engineering change process across local and remote sites
  • Access to current and accurate product data for all sites
  • Affordable, robust and scalable PLM system for start-up
  • Direct integration with existing Intuitive ERP system
  • Eliminate arduous paper-based processes
  • Eliminate replication of error-prone data

 

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Solta Medical, Inc.

Solta Medical Meets Stringent FDA Compliance Requirements for Class II Medical Device Product

 

Industry

Medical Aesthetics

 

Overview

The Thermage solution from Solta Medical is a Class II medical device and therefore is required to meet stringent Food and Drug Administration (FDA) compliance requirements. Solta Medical must have a proper document structure in place to show the history of how a product was built, with signed and dated documents.

 

Solta Medical wanted a central and secure location for all Thermage product data to be vaulted so that they could easily track, manage and find information. They also wanted to implement a system that would support better compliance and manufacturing processes.

 

Return on Investment
  • Meet stringent FDA compliance requirements (21 CFR part 11)
  • Able to complete Software Validation in short timeframe
  • Eliminate waste in manually searching for product information
  • Easy to use solution/Fast user adoption for existing and new staff
  • Superior customer support

 

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TEKTELIC Communications

Rich Feature Set, Usability and Low Cost Prove Ideal for Innovative Start-Up

 

Industry

Cellular Radio Solutions and Micro Base Stations

 

Overview

As a growing company with an experienced staff, TEKTELIC knew that a Product Lifecycle Management system was required early on, prior to their first development project, to ensure that the company had the proper product development processes in place to effectively manage part information, Bill of Materials (BOMs), and engineering changes. This positioned TEKTELIC to remain focused on delivering innovative, low cost solutions as the company grew.

 

TEKTELIC was looking for a cost effective PLM product that did not introduce significant overhead for their design staff. “We evaluated five PLM products and also considered SaaS PLM packages,” stated Trevor Zapach, Director of Operations for TEKTELIC Communications. “We rejected the larger packages due to their cost and complexity and the SaaS packages due to concerns with data security and limited CAD tool integration. We ultimately selected the solution from Omnify Software due to its rich feature set, usability and low cost.”

 

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Terrafugia

Terrafugia Takes BOM Management to New Heights with Empower PLM

Industry

Aircraft/Automotive

 

Overview

Terrafugia is developing the Transition® Roadable Aircraft to address head-on the issues private and sport pilots face with cost, weather sensitivity, high overall door-to-door travel time and a lack of mobility at destination. Its unique design allows the Transition® to fold its wings and drive on any surface road with a modern personal airplane platform. Once at the airport, the wings extend and the aircraft is ready for take-off.

 

The Transition® will be compliant with the FAA’s Light Sport Aircraft (LSA) standards. All manufacturers of LSA are required to maintain complete production documentation, including parts lists/Bill of Materials (BOMs). When new revisions of the standards become accepted by the FAA, old production vehicles still need to demonstrate line item compliance to the standards in effect when they were shipped. Initially, Terrafugia was managing their product information in a paper-based manner with automotive and aviation specifications contained in large manuals and BOMs tracked in Excel spreadsheets without any association to each other. The company needed to track this detailed and dynamic data with a more controlled and efficient method to ensure adherence to the LSA requirements.

 

“We consider it a best practice to have a digital BOM under change control. A product lifecycle management tool was therefore a very natural need for us,” stated Douglas Quattrochi, Vice President of Operations for Terrafugia. “As a small company with very limited resources, we needed to make sure that the PLM solution we purchased was intuitive, immediately configurable to our needs, and an excellent value. We found all of this with Omnify Empower PLM.”

 

The robust BOM and revision management capabilities of Empower PLM allow Terrafugia to electronically track old and new production vehicle information in a central location and with associations. Additionally, Terrafugia uses the BOM Attribute feature of Empower PLM to track the weight of each part to determine the weight of the entire vehicle/aircraft which is a critical aspect of aircraft development. This information provides greater insight to the BOM and better design control.

 

Return on Investment

  • Electronic system for efficient BOM/parts list and change management
  • Intuitive, configurable and affordable PLM solution for small company
  • Support compliance with FAA regulations
  • Better design control

 

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Treske Precision Machining, Inc.

Treske Precision Machining Implements Omnify in Less Than a Week and Shortens Engineering Change Cycles by over 75%

Industry

Manufacturer of Precision Machined Parts, Welded Frames, and Integrated Assemblies

 

Overview

A substantial growth in their customer base and pending ISO certification changed Treske’s requirements for managing product information. Legacy processes were no longer sufficient to keep up with the significant increase of documentation that needed to be managed. Treske’s product documentation was stored in various files on network servers; Bills of Materials (BOMs) were managed in Excel spreadsheets and prints were saved in PDF format. This setup lacked accessibility and the capabilities to keep documentation in a controlled environment such as tracking, linking and where-used searching.

 

Treske had implemented an Enterprise Resource Planning (ERP) solution from Epicor Software Corporation, Epicor Vantage® 8.0, to manage manufacturing information such as job planning, purchasing, inventory and financial data. Treske knew the best way to manage their growing product information and properly track documentation for ISO certification was to employ a Product Lifecycle Management (PLM) solution. Treske’s ultimate goal was to integrate the ERP and PLM environments to directly share information through an automated process and eliminate double entry of part data. Treske enters new part data on a daily basis and manually entering that data into two systems is error-prone and time-consuming. Treske wanted all released information, particularly BOMs, automatically uploaded to Epicor from the PLM system.

 

Omnify supplied Treske with a PLM solution that met all of their requirements: an open integration platform, ease of use, low cost, and an outstanding support team.

 

Return on Investment

  • Fast implementation and training (under one week)
  • Reduced ECO cycle time by over 75%
  • Unified location to manage product information
  • Ensure accuracy of data across the enterprise
  • Reduced product returns
  • Eliminate delays in searching and accessing product information
  • Supports ISO certification requirements

 

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Vergent Products, Inc.

Vergent Products, Inc. Improves Product Quality and Customer Collaboration

Industry

Design and Manufacturing Services

 

Overview

Vergent manages multiple customers and products in both development and assembly. Data is received in various file formats and revisions and communication between Vergent and their customers is critical. The company was tracking and managing Engineering Change Orders (ECOs) on a shared Excel spreadsheet which resulted in a variety of problems.

 

With a focus on consistently producing quality products, on time, Vergent was looking for better methods to process ECOs, track releases of documents related to products, control document revisions with a repository for those documents, as well as a means to improve collaboration with their customers.

After seeing a demonstration of the Omnify Empower PLM system, Vergent knew it was exactly what they needed to address their product development issues.

 

Vergent has over 60 employees using the Omnify Empower PLM system including: Sales, Service, Engineering, Purchasing and Production. The company is leveraging the core features of Empower PLM to support controlled processes such as; item and Bill of Material (BOM) creation, engineering changes, file management, revision control, approval history, task management, and document control. The company has also expanded their use of Omnify Empower PLM with the Quality Management and Project Management features.

 

Return on Investment
  • Eliminate lost time searching for status of Engineering Change Orders (ECOs)
  • Reduce material scrap and incorrect orders by 96%
  • Reduce paper, printing, ink, and shipping costs
  • Reduce scrap and re-work
  • Improve communication with customers/customer satisfaction
  • Improve document control
  • Support consistent product quality
  • Faster New Product Introduction (NPI) cycles

 

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Vessix Vascular

Hot Medical Device Start-up Prepared for Growth and Compliance

 

Industry

Medical Device

 

Overview

Vessix Vascular is a privately-held, venture-backed company developing novel radiofrequency balloon catheter technology directed towards a variety of clinical applications including the treatment of medication resistant hypertension via percutaneous renal denervation, and peripheral in-stent restenosis.

 

Comprised of a group of individuals with previous experience at successful medical device companies, one of their first priorities was to formalize their product development processes to prepare for their market introduction, successfully meet regulatory guidelines and implement best practices early on.

 

Vessix selected the Empower PLM solution because it met their needs as a small start-up with an easy to use and configure system and also delivered the features they needed for controlled product development processes to meet compliance requirements. The scalability of Empower PLM ensured Vessix that they would be able to continue to use the tool as the company grew.

 

Return on Investment

  • Implement product development best practices early on
  • Affordable, scalable and robust PLM solution for start-up
  • Time to process ECOs is transparent
  • Simplified audit processes/meet compliance requirements
  • Dynamic vendor management provides visibility into all vendor associated parts and assemblies
  • More efficient machine calibration and preventive maintenance process

 

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XEI Scientific

XEI Scientific Implements Controlled Processes and Improves Profitability in Tough Economy

 

Industry

RF Plasma Cleaning Systems for Electron Microscopes and High Vacuum Systems

 

Overview

As an emerging company, XEI Scientific had a small staff, heavy workload and limited bandwidth. They did not have time to organize product data, leaving it scattered across multiple computers and in different formats. Finding data was a time-consuming and cumbersome task without any guarantee that the information was current.

 

The company discovered that a Product Lifecycle Management (PLM) solution would provide the data management capabilities they were looking for. XEI set out to find a product to meet their specific needs as a growing company. XEI wanted an affordable PLM product that would scale as the company grew.

Centralizing product information within Omnify improved collaboration and made accessing data a simple process. This environment helped XEI to reduce errors and costly rework, resulting in a higher quality product for their customers. XEI has also realized significant savings in overhead, allowing them to grow and improve profitability despite the recession by keeping costs and headcount down.

 

With over half of their sales overseas, XEI needs to assure the design and manufacture of compliant products. During XEI’s Nationally Recognized Testing Laboratories (NRTL) inspection, the auditor was impressed with how XEI managed approved vendor and parts lists in Omnify as well as BOM Versioning and ECO processes. The auditor was also pleased with XEI’s use of Omnify as a document control system for assembly and test procedures and documentation for customers, such as user manuals and software.

 

Return on Investment
  • Reduce time searching for product information
  • Eliminate scrap and rework
  • Significant overhead savings
  • Help decrease cost of goods by over 20%
  • Cut compliance certification time by 50%
  • Maintain profitability in tough economy

 

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Z Microsystems

Z Microsystems Automates Training Processes and Gets "Pat on the Back" From ISO Auditor

Industry

Field-ready computing solutions for military, medical, industrial, and law enforcement applications

 

Overview

Z Microsystems has been successfully using the Omnify Software Product Lifecycle Management (PLM) solution to help manage and control their product life cycle for a little over six years. With the release of Omnify Empower PLM, new product features, specifically Training Management, became very valuable to the organization in addressing issues beyond their initial Product Lifecycle Management requirements.

 

With success managing their product design and development processes via Omnify, Z Microsystems turned to this system to address their outstanding ISO (International Organization for Standardization) compliance issues.

 

Return on Investment

  • Meet ISO compliance requirements
  • Automate and streamline training processes
  • Update outdated Stanard Operating Procedures (SOPs)

  • Remove unecessary hard copy documents from the floor
  • Improve team collaboration with automated change alerts

  • Save time with single document master list
  • Improve document control

 

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Seahorse Bioscience

World leader in tools for cell metabolism researchconsumable labware products for biological research and drug discovery.

Industry

Medical Device-Biological Research and Drug Discover Products.

Overview

Serving the life sciences industry since 2001, Seahorse Bioscience provides industry-leading analytical instruments, biomanufacturing systems and consumable labware products for biological research and drug discovery.

 

Seahorse Bioscience was managing product development with paper-based processes. Information such as part numbers and Engineering Change Orders (ECOs) were processed using Excel spreadsheets. This eventually became inefficient, risky and laborious. In addition, the company had two corporate divisions. With the data spillover that can result from any collaborative work
between multiple corporate divisions, a Product Lifecycle Management (PLM) system became a necessity in order to centralize and control information.

The company’s primary goal was to find a means to centralize and automate their document control tasks. They wanted to have one corporate source for part number generation, ECO generation and tracking, and a secure corporate repository for design/product data with automated revision control.

Return on Investment

  • Replace error-prone Excel-based part generation and ECO processes
  • Keep product data for two corporate divisions in sync
  • Eliminate issues with misplaced or forgotten ECOs
  • Eliminate purchasing out-of-rev parts and assemblies
  • Guarantee vendors are using the latest revision
  • Streamline design and manufacturing information
  • Integration with corporate ERP system, Infor Syteline

 

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Axonics Modulation Technologies

Privately-held medical device company developing an innovative neuromodulation platform based on miniaturized rechargeable technology. 

Industry

Medical Device

 

Overview

The team at Axonics had previous experience with Product Lifecycle Management (PLM) at another medical device start-up. They knew the benefits that an electronic, online PLM solution could provide a small to medium-sized medical device company.
 

One particular area where Axonics saw the greatest benefit of a PLM solution was with electronic sign-offs. With paper-based processes and insufficient signatories, approvals are serial in nature and the absence of a key approver can translate into a major delay. Axonics wanted to prevent this issue with an automated system that offered the ability for Axonics staff to continue the approval process for documents/drawings/training/etc., on or off-site, via remote logins and allow for the assignment of signatories.

 

Axonics wanted a software solution that would facilitate Active Implantable Medical Device (AIMD) product development under a Quality System compliant to ISO 13485 and the FDA CFR (Code of Federal Regulations), as well as other regulatory frameworks.

 

"We were told by industry experts that a new Sacral Neuromodulation product would take five years to receive CE marking, but we accomplished that milestone in just two years after initiating design controls with Omnify Empower. Omnify facilitates rapid design, document, and BOM controls in tandem with supplier approvals and vendor item linkages. All these aspects and more allow us to achieve our ambitious timelines."

 

Key benefits

  • Flexible and configurable system for growing medical device company
  • Fully implemented in only a few weeks
  • Able to receive CE marking in just two years compared to industry average of five years
  • Met goal of having an automated system for electronic sign-off with signatories
  • ISO 13485 and FDA CFR-compliant Quality System
  • Established Design Controls

 

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