Maintenance Process Reinvention for High-Performance Semiconductor Pioneer (Lumileds)
Case in point: Lumileds
At a glance
Focus: Maintenance Process Reinvention for High-Performance Semiconductor Pioneer (Lumileds)
Challenge: Lumileds had difficulty managing maintenance due to the significant number of machines on each site and a heavy, paper-based maintenance process — with over 1,000 machines at the Singapore location alone, each requiring specific and detailed care.
Approach: The key issue was to digitalize this paper-based process and make the information accessible via any device, engaging Arcstone for operational functions and preventive maintenance, integrating Arcstone's Equipment Maintenance System toolset with Lumileds' existing MES.
Impact: Especially during COVID-19, the initiative was extremely beneficial in managing equipment maintenance — reducing indirect workload by 14%, saving 30% of workforce time (motion waste), cutting report creation time by 4 hours/day, and decreasing maintenance transaction time by 25%.
Arcstone
Arcstone is a leading manufacturing software company with a mission to provide complete manufacturing transparency across the entire supply chain. As the partner of choice for manufacturers looking to grow and be at the forefront of digital manufacturing innovation, Arcstone aims to simplify Industry 4.0 and enable a more responsive, responsible, and sustainable manufacturing ecosystem for everyone by digitizing and integrating manufacturing operations from the shop floor right to the hands of consumers.
Lumileds
Lumileds, a global lighting solutions company, started their digital transformation journey in 2018 as they prepared to scale their efforts to be a leader in the data-driven manufacturing space across their facilities globally. Lumileds is the leader in LED solutions, specifically in high performance LEDs for automotive lighting, general lighting and specialty lighting.
The transformation started at the Singapore and Penang locations that focus on wafer and die fabrication of Lumileds high performance LEDs. The business case for this digital initiative focused on productivity and time saved in terms of data analysis and ability to track historical performance.
Business challenge
Lumileds had difficulty managing maintenance due to the significant number of machines on each site and a heavy, paper-based maintenance process — with over 1,000 machines at the Singapore location alone, each requiring specific and detailed care.
Lumileds had difficulty managing maintenance due to the significant number of machines on each site and a heavy, paper-based maintenance process.
o With 1,000+ machines in the Singapore location alone, and each machine requiring specific and detailed care, Lumileds discovered that digital transformation was very much needed.
Industry 4.0 solution
The key issue was to digitalize this paper-based process and make the information accessible via any device. Other key aspects were on preventative care and maintaining efficiency.
Lumileds had engaged Arcstone for operational functions and preventive maintenance. Lumileds team was also invited to view Arcstone’s demo centre in Singapore and were introduced to Arcstone’s Equipment Maintenance System toolset.
The aim was then to digitize their scheduling and checklist functions, to integrated Arcstone’s solution with their own MES.
Key benefits
| Area | Outcome |
|---|---|
| Downtime & Reliability | Especially during COVID-19, the initiative has been extremely beneficial in managing equipment maintenance. As the amount of personnel in the factory at one time has been limited, digitalizing the system has made it easier for personnel to cross train, track performance, share tasks and coordinate some maintenance activities remotely to support production as well. |
| Operational Benefit | Short-term Reduced indirect workload by 14% |
| Safety & Workforce | 30% workforce time saved (motion waste) |
| Time & Speed | Decreased report creation time by 4 hours/day |
| Downtime & Reliability | Decreased maintenance transaction time by 25% (in minutes per machine) |
| Quality | Long-term Increases in data analysis quality |
| Downtime & Reliability | Improvement in preventive maintenance |
| Operational Benefit | Company-wide transparency, communication and connection. |
Technologies used
Change management and implementation
Engage Arcstone as implementation partner
Lumileds engaged Arcstone for operational functions and preventive maintenance, kicking off the partnership focused on digitalizing their paper-based maintenance process.Demo center visit & toolset introduction
The Lumileds team visited Arcstone's demo centre in Singapore and was introduced to Arcstone's Equipment Maintenance System (EMS) toolset to evaluate its capabilities firsthand.Pre-project interviews, POC & technical demos
The Arcstone project team carried out pre-project interviews, a proof of concept, and technical demos to validate the approach before full deployment.Digitize scheduling/checklists & integrate with MES
The primary technical goal was set: digitize Lumileds' scheduling and checklist functions and integrate Arcstone's Equipment Maintenance System with Lumileds' existing MES.Integrate legacy systems while meeting TS 16949 standards
To handle the integration of multiple existing legacy systems and meet TS 16949 automotive audit standards, Arcstone's hardware- and software-agnostic solution was used to seamlessly connect with Lumileds' legacy systems.
Deploy dashboards & reporting for real-time visibility
Dashboard and reporting tools were deployed to give Lumileds full, real-time data visualization and reporting, enabling activity retrieval and recording for future audits.
Change management & workforce training
Change management was handled through early, continuous engagement with internal teams and targeted training for staff facing new responsibilities, rolled out with room for review and course correction.
Scale to remote/cross-trained operations (COVID-19 resilience)
Especially valuable during COVID-19, the digitalized system enabled remote coordination, cross-training, and task-sharing among maintenance personnel to keep production supported despite limited on-site staff.