Challenge – traceability, labor utilization, rework, and reconfiguration
The story starts with the technology that Viavi, a top urban network communications provider, relied upon to manage its manufacturing operation. Historically, this was a solution developed in-house, and one that continued to grow over time to meet an ever-changing strategic outlook – including acquisitions that further expanded their IT landscape. All of which meant that Viavi boasted a disparate tech environment that appeared front and centre on the corporate risk register:
- The solution was not up to the task of managing the complex monitoring required to ensure cradle to grave traceability of all products
- The UI was clunky and difficult to use, and offered users only limited functionality
- Users were being forced to use multiple applications and software solutions to carry out their daily tasks, which in turn was creating an efficiency bottleneck
Not that the problems stopped there. Viavi was also experiencing issues with planning (both for manufacturing ops and labour requirements), which was being carried out via spreadsheets — meaning a manual, often disconnected task that was prone to human error. The siloed systems also made it difficult to create accurate reports on labour utilisation, rework, reconfiguration and other KPI’s.
Then there was traceability, and ensuring the integrity of the data record surrounding products both during manufacture and throughout its operational life. This requires a lot of data collection and analysis to maintain visibility of all parts and serial numbers (including upgrades). Put simply, the existing system was struggling under the weight of information it had to hold, and the fact that it was offered little visibility of what new orders would land – and the precise configurations involved.
Greater agility was therefore required from the system to maintain end-to-end product traceability. But more than this, Viavi needed a dynamic view of what resources were being used, when, and where. A view that enabled them to make changes on the fly, and to see the repercussions of any variations in plan. In short, they needed a new manufacturing execution system (MES). A decision that soon led them to Eyelit Technologies (Eyelit) due to the fully supported, cloud-based offering that removed the management and resourcing headache for Viavi – whilst giving them capabilities to track every part in every production process.
Solution – MES integration with Oracel E-Business Suite
“It was one of those situations where we didn’t know what we didn’t have, because we hadn’t experienced it yet. But now I honestly don’t know how we worked without Eyelit.”
– Jonathan Morley, GCUK Head of Engineering at Viavi Solutions
As with all our client engagements, Eyelit didn’t turn up at Viavi with an out-of-the-box solution. Instead, we began with a detailed scoping workshop to explore what was needed and why. This is an important point, as only then can an organisation feel empowered to configure the MES to fit their current operations – rather than the other way around.
Moreover, the team at Viavi can now call upon a more visually-intuitive, user-friendly system that integrates seamlessly with their internal ERP software Oracle E-Business Suite. The result is a new, interconnected MES capability that’s helped focus performance across 7 key areas:
1. Delivering a Single, Consolidated System for All Workflows
Using the Eyelit Technologies MES solution, the team has been able to say goodbye to spreadsheets and the previous home-grown system. Now all planning, manufacturing and subsequent field maintenance is performed off one single source of information.
2. Long-Term Rough Cut Capacity Planning (RCCP)
The Eyelit Technologies MES solution comes with built-in RCCP planning capabilities, including whatif scenario analysis and forecasting tools capable of covering up to 2 years in duration, as well as live project and task scheduling dashboards. The system is also updated with information straight from the factory floor and the field, so all data is real-time — making rough-cut capacity planning both possible and practical.
3. Iterative Change Tracking to Maintain Visibility Across Projects
The Eyelit Technologies MES solution’ record-keeping system makes it easy for the team to track improvements and changes across constant design changes, for improved accountability and understanding. This allows Viavi to run different designs in parallel and complete tests with ease. Another big plus is that product specifications, not always known at the time of planning, and can be modified mid-manufacturing flow – and constantly recorded.
4. Configurable Dashboards for Easier Analytics and Reporting
The new MES software comes with a better, more user-friendly user experience and powerful BI tools. While the system was configured to meet Viavi’s needs from day one, it also supports dynamic configurability with sleek dashboard building capabilities. Users can adapt these on demand, which makes reporting and data analysis a far easier and more efficient process.
5. Enabling Better Team Planning and Workforce Optimisation
With data on manufacturing progress and labour all consolidated in one place, users can actively monitor team productivity and resource allocation down to the granular level. What’s more, dashboards are now used to display live charts of workforce optimisation at the function, team, and individual level.
6. Track and Trace Available for Field Engineers Globally, Anytime, Anywhere
The cloud-based nature of the new MES solution means it can be used by any employee regardless of their location. This asynchronous workflow enablement makes it easy for field operatives to log in and check serial numbers and tasks on the go — confident that all the information surrounding their work is automatically updated in the system.
7. Improved Monitoring and Accountability Across the Whole Lifecycle
The goal here being to support cradle to grave traceability for all products, to help meet compliance obligations and realize Viavi’s ambitions for net zero emissions and integration into the circular economy. Now with Eyelit, the company can monitor remotely all changes, failures and upgrades for the duration of the product lifecycle. Records of specific parts and modifications are also tracked through the system until obsoletion and final disposal.
Results – full traceability, improved master resource allocation, reduced costs, improved on-time-in-full deliveries
Using the Eyelit Technologies MES solution, the team has been able to increase efficiencies from the office to the field. The automation and analytics capabilities built into the system have made it easier for users to analyse all aspects of performance, and report and respond on the findings in real time.
Traceability, and quality control has also greatly improved, with all the relevant data being comprehensively tracked and available for instant review. This improved visibility has also helped Viavi improve the deconstruction and end-of-life process for products, thereby ensuring all components are disposed of, recycled, or reused whenever possible.
Another big benefit comes in the form of full visibility into labor utilization, which is now on hand to help Viavi master resource allocation and interdependencies – thereby reducing costs and improving On-time in-full deliveries. Such visibility is also mirrored across supply chain operations, as the business continues to drive continuous improvement activities. All of which is creating the real-time pool of data insights needed to identify future projects, and to support the business cases for seeking further efficiencies and boosts in productivity.
Benefits Showcase
- One platform for all workflows – managed and maintained by experts
- Reporting now takes minutes rather than hours
- No need for on-premise hardware and investment
- Full utilization of cloud security and accessibility
- Customisable dashboards delivered either by Eyelit, or with data extracted into any data lake – depending on the architecture involved
- Enhanced sustainability performance and progress toward net-zero goals
- Regular upgrades – ensuring the efficiency of the autonomous database transactions are benefiting from the very latest in Oracle E-Business Suite
- Constant innovation of Viavi’s Azure front end, and delivering new functionality as other client improvements are incorporated into the core product
About Viavi Solutions
Chances are you’ve never heard of Viavi Solutions, but what they do is critical for enabling the modern world of seamless network connectivity. A purpose made possible by their work with a host of clients ranging from social media giants to leading telecom companies. Where Viavi helps is to simulate and monitor digital activity across entire cities, and to stress test a network to its fullest capacity.
It’s this capability that positions the company as a crucial link between cutting-edge mobile platforms extending from 3G to the furthest frontier of 6G technology. So when a customer wants to offer reliable services across an urban environment, they can do so with confidence after rigorously testing all aspects of performance. That’s the Viavi difference, and quite rightly they’re rather proud of the difference this makes.