WIPtrac is software for Work in Process Factory Floor Control Manufacturing Execution Manufacturing Operations Management

WIPtrac is a Work In Process (WIP) factory floor control system / Manufacturing Execution System (MES) targeted towards high tech manufacturing environments such as Semiconductor fabs, MEMS fabs, semiconductor assembly backend and research & development environments with:

• Integrated SPC Quality, Engineering  Data Collection
  
  
• On-line Manufacturing Instructions  Documents and Drawings
  
  
• Equipment Tracking, History and  Preventative Maintenance scheduling
  
  
• Operator Qualification Tracking       ...and so much more

WIPtrac runs in Internet Explorer, Firefox, Safari and on your iPad and smart phone. It can be installed behind your factory firewall and can run securely with a VPN across the Internet. All you need is an Internet connection and you can begin to configure your factory today.

Every component of WIPtrac is fully-configurable from inside the onscreen menu structures. No outside programming is required. No in-house software experts are needed. WIPtrac is suitable for both large and small fabs.
WIPtrac provides:

• 80% of the Functionality at
• 20% of the Price and is
• 200% easier to Configure and Maintain than any other true MES ERP           MRP solution that you can find. Guaranteed.

Traveler Capabilities  

WIPtrac is driven by a traveler- or router-based factory organizational strategy. Product moves through your factory under the direction of barcoded travelers created by WIPtrac. WIPtrac can be used run paperless. Flexibility is built in with alternate, optional, and forced out of sequence steps. As Built History is always captured. Traveler revisions and maintenance are under the control of your configuration management team.

Work In Process WIP Capabilities

WIPtrac has extensive Work In Process tracking and reporting features showing WIP items like parts moved, good parts out, rejects, reworks, transferred to rework and much more. The reporting system for WIP data allows you to slice and dice your data in unlimited ways across unlimited numbers of parts and it is all exportable to Excel spreadsheets with a single mouse click.

Statistical Process Control SPC, SQC and QMS Capabilities

Statistical Process Control (SPC), Statistical Quality Control (SQC) and Engineering Data Collection (EDC) becomes a valuable part of factory management as WIPtrac collects, analyzes, monitors, generates warnings, sends alert e-mails and text messages and even shuts down lots, operations or equipment based on incoming SPC data. The paper blizzard associated with engineering data collection is over when you use WIPtrac to handle the information.

Electronic Quarantine Features

There are 5 levels of hold available within WIPtrac. They can be used for Material Review Boards (MRB) or Engineering Change Orders (ECO) or Process Engineering Holds (PEH) for operations review or for any other purpose you might wish the system to stop work.

• Put Lot on Hold
• Put Lot on Future Hold
• Put Part Number on Hold
• Put Operation on Hold
• Put Equipment on Hold

Lot Number Hold, Operation Hold and Equipment Hold can trigger automatically if SPC or engineering data goes out of control. When this happens, WIPtrac will send e-mail and text messages to the appropriate parties.

Operator Qualification Enforcement

Operators are assigned a qualification status for different operations and processes in the factory and the operator will not be allow to check into operations for which WIPtrac does not have them qualified.

ISO 9000 and ISO 9001 Configuration Management Features

ISO 9000 and ISO 9001 compliance is supported via complete configuration management system, modeled after similar paper systems. Operations, parts and part numbers, travelers and traveler numbers, etc. cannot be used by WIPtrac until they have been released. For example, once a new traveler has been reviewed and approved, configuration management personnel with the right security level and system password will release the traveler for use by factory floor operators.

Equipment and Tool Tracking and Preventative Maintenance

Equipment Tracking allows equipment and tools in your factory to be associated with multiple processes and operations. Likewise operations and processes can be associated with multiple pieces of equipment.

WIPtrac keeps a running total of what product and what quantities are produced by the equipment. Preventive maintenance triggers can be set for volume processed, runs initiated, time passed, SPC limits exceeded and others. If a tool goes down for maintenance either by triggering a limit or scheduled preventive maintenance, e-mail and text message notifications are sent to the appropriate parties.

Bar Code Enabled

WIPtrac was designed from the ground up to be bar code driven. WIPtrac generates bar code labels for you on any printer, using any desired format, readable by a myriad of different bar code wedges and readers.

Scheduling Capabilities

Using work content on travelers, WIPtrac predicts a ship date when a lot is kitted to the line and then constantly updates the predicted date while letting you know just how much ahead or behind the lot is running. Special on-line dispatch lists and reports give operators a quick look at what is in their queue at their workstation and from this list they can choose the hottest lots currently on the line to work on next. WIPtrac can be configured to e-mail daily alerts for manufacturing lots that are stalled and not moving.

     It's all here and ready to use. If we can help in anyway please
     give us a call... or send us an e-mail.

SPC and Engineering Data

Engineering Data Collection (EDC) can occur every time parts are processed through an operation in the factory.

From the convenience of a computer terminal, your engineering and production control department can review up to the minute process data from factory operations. Track process data like:

• Control Limits
• Spec Limits
• Cp and Cpk
• Std Deviations
• Sigma
• Frequency Distributions
• Ranges
• Correlations
• User defined calculations

WIPtrac automatically keeps track of operations and sends alarms via e-mail and text messages when these process parameters go out of specification.

Statistical Process Control is the key to a quality product, shipped on time. When a process goes unmonitored, unmeasured and uncorrected, very large and unpredictable swings in both quality and quantity will occur.

Knowing where the product is in your factory, knowing when the product is going to ship and other critical information allows managers to make informed, competent decisions. However, SPC information about your process is just as important as Production Information.

WIPtrac supports and augments quality systems presently in place in high tech / high reliability manufacturing environments. WIPtrac delivers many features in support of ISO 9000 and ISO 9001 for plants looking to implement or upgrade a quality system.

• Enforces onfiguration management systems.
• Collects and analyzes SPC data automatically.
• Enforces manufacturing specifications.
• Enforces operator qualification status.
• Keeps manufacturing process, procedures, drawings and technical specifications on-line at all times.
• Makes quality auditing possible where it was previously a chore.
• Easily configured

Configuration Management

WIPtrac is built from information supplied to it by the user. WIPtrac knows nothing about your factory until you build up a list of manufacturing operations that are performed by your shop floor employees. This list holds information like: charge number, process/operation number, revision level, default technical specs, and document and drawing numbers necessary for the operation.

As each operation is entered into WIPtrac, it must go through a release cycle similar to the release cycle used for paper document systems. The significance of this is that operations can only be released by your Configuration Management department with the release code for WIPtrac and the software will only allow for released operations to be included in routings or travelers. Like operations, routings and travelers must go through a release cycle before WIPtrac will allow them to be used on the factory floor. This system of release authorization enforces compliance to Configuration Management principles.

SPC Data Collection and Analysis

When a process goes unmonitored, unmeasured and uncorrected, very large and unpredictable swings in quality and quantity will occur.

SPC is a key element of WIPtrac and is integral to the way the system works. Engineering Data Collection and Analysis occurs every time parts are processed through an operation in the factory. From the convenience of a computer terminal, your engineering department can review real-time data from factory operations and dump data out to Excel spread sheets and statistics software packages.

Operations have data value control limits, range value control limits and spec limits that can be used to control your factory. As data is collected, it is compared against the three types of limits and depending upon which values are exceeded or violated, different actions can be triggered. The system can be configured to automatically put operations, lots and equipment on hold that violate the limits. WIPtrac uses the WESTERN ELECTRIC "RUN RULES" to determine if data is out of control. This refers to the data that exceeds limits as well as the 2 out of 3, 4 out of 5 and 8 in a row methods of detecting unstable processes.

Manufacturing Specifications Enforcement

Engineering Data Collection (EDC) occurs every time parts are processed through an operation in the factory. From the convenience of a computer terminal, your engineering and production control departments can review up to the minute process data from factory operations. WIPtrac automatically keeps track of operations and sends alarms by e-mail or text message when process parameters go out of specification.

Knowing where the product is in your factory, knowing when the product is going to ship and other such information is critical in helping managers make informed, competent decisions.

However, information about your process is just as important as production information. Process control is the key to a quality product, shipped on time. When a process goes unmonitored, unmeasured and uncorrected, very large and unpredictable swings in both quality and quantity will occur.

Integrated SPC is a major benefit of running WIPtrac Manufacturing Execution Systems.

The Barcoded Traveler Controls the Flow

WIPtrac traveler and router-based tracking and control uses an ordered list of steps (as seen in the example below) to route and control lot-based manufacturing.

One swipe of the barcode wand for Lot M2-180 (as shown in this example) brings up As Built Lot History and Next Expected Steps below the green line.

View Traveler Full Screen View Traveler Full Screen

And here is a typical example of a video that might be part of a manufacturing instruction for the operator to review.

 

A Short -- How It Works -- Video

This 1:30 minute video gives you a look at WIPtrac the way an operator experiences it.

5 Steps to Configure WIPtrac - a short video

This 90 second video takes a high speed cruise through a basic WIPtrac configuration.

Classic Trend Charts

The trend chart shows spec limits, control limits, averages, sigma, standard deviations, min and max data points, Cp and Cpk values and it can all be output to tabular formats and Excel spreadsheets. View Trend Chart Full Screen View Trend Chart Full Screen

Classic Frequency Distributions

The frequency distribution charts allow the user to look for things like bi-modal distributions and long tails in the data set that can be useful in understanding how a process is running. And like the trend chart it also shows spec limits, control limits, averages, sigma, standard deviations, min and max data points, Cp and Cpk values that can all be dumped to tabular formats and Excel spreadsheets.
View Frequency Distribution Full Screen View Frequency Distribution Full Screen

SPC Monitor Screens

Users can configure custom monitor screens that examine only the SPC Data of interest to that user. In this example you can see that some of the data items being monitored are Out of Spec (Red), others are In Control (Green), and still others have no limits set for the chart data (Pale Yellow). Clicking on the chart icons in the Monitor report opens up the SPC Chart for further review.

Full Screen Monitors View Full Screen Monitors View

When a process goes unmonitored, unmeasured and uncorrected, very large and unpredictable swings in both quality and quantity will occur.

WIPtrac lets the users perform correlation analysis, looking for relationships between various data points being collected. In this example there is weak correlation between Wavelength of Light and Brightness measured on a batch of LEDs, (Light Emitting Diodes).

Full Screen Correlation View Full Screen Correlation View

When a process goes unmonitored, unmeasured and uncorrected, very large and unpredictable swings in both quality and quantity will occur.

Equipment Tracking

Equipment tracking allows equipment / tools in your factory to be associated with multiple operations and operations can be associated with multiple pieces of equipment. When checking in, logging in or moving in to an operation, the operator chooses from the list of available equipment and begins working on their lot.

On Check Out, Log Out or Move Out, equipment history is updated, the total volume of product produced is updated and the preventive maintenance limits on equipment usage is checked. If limits are exceeded the equipment can be configured to go down for preventive maintenance (PM). The Equipment History is always available and linked to the lots that were produced by the equipment. Likewise you can schedule PMs in advance and WIPtrac can even watch and bring equipment down for PM if too much time goes by without attention from maintenance crews.

By using Santa Barbara Analysis's ("SBA's") WIPtrac web site, you agree to the following Terms of Use. If you do not agree with these terms, promptly discontinue use of the web site and do not read or download any further information from the web site.

SBA owns and operates this web site. All of the information contained in the web site is SBA's property unless indicated otherwise. You may view and download information from this web site for your personal, non-commercial use as long as you retain with it the information regarding SBA's proprietary rights, including copyright notices. You may not modify the information contained in the web site. Modification or unauthorized use of the information is a violation of U.S. copyright law and other proprietary rights. Graphics presented at this site may not be reproduced without written permission from SBA.

The content of any comments, suggestions, questions, information and feedback received by SBA shall be deemed to be non-confidential. SBA shall have no obligation of any kind with respect to such information and shall be free to use, disclose, reproduce and distribute the information to others without limitation. Further, SBA shall be free to use any concepts, ideas, know-how or techniques contained in such information for any purpose whatsoever, including, but not limited to, developing, manufacturing and marketing products incorporating such information. SBA shall be free to use information related to the electronic statistical usage of its web site by others.

WIPtrac.com is an extension of this web site where users can Test Drive SBA software. SBA has provided links to other web sites solely for your convenience. When you use these links, you leave SBA's web site. SBA is not responsible for the content of these other sites, and you access and use them at your own risk.

SBA may change the products, services or other material described or contained in the web site at any time and for any reason.

THE INFORMATION PROVIDED IN THIS WEB SITE IS PRESENTED "AS IS" AND WITHOUT ANY EXPRESS OR IMPLIED WARRANTIES OF ANY KIND INCLUDING, BUT NOT LIMITED TO, WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR NON-INFRINGEMENT. IN NO EVENT SHALL SBA BE RESPONSIBLE FOR DAMAGES OF ANY NATURE WHATSOEVER RESULTING FROM THE USE OF OR RELIANCE UPON THIS INFORMATION.

SBA makes no representations and disclaims all warranties of any kind to users and third parties as to the accuracy, completeness or timeliness of the information on this web site or the fitness of that information for any purpose. SBA will not be liable in any way for any lost profits or savings, or any other consequential, incidental or punitive damages whatsoever based on the information in this site, even if SBA has been advised of the possibility of such damages. The statements herein are for informational purposes only and do not constitute an independent product warranty. Customers with warranty-related concerns should consult their SBA software license agreements. All responsibility or liability for any damages caused by viruses contained within the electronic files or at the site is disclaimed. Information contained in the web site includes statements that are forward-looking. Actual results could differ materially from those projected in the forward-looking statements. The trademarks, logos, and service marks (collectively the "Trademarks") displayed on this web site are registered and unregistered Trademarks of SBA or others. Nothing contained in this web site should be construed as granting, by implication or otherwise, any license or right to use any Trademark displayed on the web site without prior permission of SBA or such other Trademark owner. Although SBA regularly and frequently deletes old information on its site, site visitors should assume that information contained on the site is current only as of the date such information was posted. Any disputes which may arise out of, result from, or are in connection herewith shall be brought exclusively in the state or federal courts located in Los Angeles County, California. User agrees and consents to venue in Los Angeles County, California and the in personam jurisdiction of the aforementioned courts. The language in this disclaimer shall be interpreted as to its fair meaning and not strictly against SBA. SBA may modify these Terms of Use at any time. In addition, other terms of use may be contained throughout the web site. Please revisit this page periodically to check its modification date and be aware of the other terms of use contained in the web site.

January 1, 2012