A high-value electronics manufacturer was experiencing significant downtime driven by out-of-control process (OCAP) alerts. When an alert was triggered, production was halted, and the operator and engineer researched and addressed the issue before production resumed

The process measured hundreds of specifications across 400 tools based on a combination of manual tracking and data
from various machines, tools and business systems. The standard operating procedures (SOPS) were paper-based and were infrequently updated. Operators and engineers relied on tribal knowledge and personal experience to find and address the issues, which was time consuming