SUCCESS STORY

Developed automated testing, streamlined firmware management, and sorted and labeled RGM products

Industry

Manufacturing

Country

United States

Company size

1001 - 5000 employees

About NetGear

The client (NETGEAR) is a multinational computer networking company in the US, producing networking hardware (e.g. wifi router, camera, etc.) for consumers, and businesses

Industry

Gas & Oil

Country

Us

Company size

45.000 employees

Website

About Halliburton

Halliburton Company is an American multinational corporation and the world’s second largest oil service company and responsible for most of the world’s largest fracking operations. The company helps customers maximize value throughout the lifecycle of the reservoir – from locating hydrocarbons and managing geological data, to drilling and formation evaluation, well construction and completion, and optimizing production throughout the life of the asset.

The Challenges

Return goods materials (RGM)

  • The customer’s product testing system wwas quite slow, only allowing for one product to be tested at a time. This delayed the time to market for the product.
  • Untested goods accumulated leading to warehouse storage costs.
  • The large workforce resulted in many manual operations, which were prone to errors, leading to reduced productivity.
  • Updating the software with new versions took a lot of time and was not consistent.

The customer desired o build a system for classifying returned products for re-entry into the market, minimizing human errors, accelerating time to market, and optimizing labor resources

ShopFloor Control System (SFCS)

  • Manual control of the testing process for each product through labeling made the products prone to loss and confusion during the testing process. Customers had to spend additional time rechecking the system, leading to decreased productivity and increased labor costs.
  • The system was unable to accurately determine the PASS or FAIL status of a product during the testing process
  • The process management system for each product’s testing was not optimized. The customer would incur additional costs to expand the system if production were scaled up

The desire was to build a system that could be easily reused on existing systems, with fast deployment, easy scalability and upgrades, cost reduction, labor optimization, and increased efficiency

The Solutions

  • Developed automation test systems that could handle more products at the same time
  • Built a new software application to be able to manage and update software/firmware for multiple devices simultaneously to help optimize cost and make time-to-market faster.
  • Builtand deployed a new software application to be able sort RGM products, manage and automatically apply the product life cycle for each kind of product (such as: A-Grade, B-Grade, RB-Grade, S-Grade).
  • Built a tool of Serial Number Generation to label a new SN for RGM device package before delivering to market.
  • Built a system to manage inspection processes and query all of the products at the factory (Check status of the product, Initiate product inspection process, determine the testing process for each product, Export reports for each process)

The Results

  • Categorized returned products according to clients’ classification criteria
  • Reused products, ensuring they are still in working condition for the market, minimizing inventory losses
  • Enabled to test 10 products per testing session, reducing the time to market
  • Increased revenue without incurring inventory costs.
  • Helped the client (NTGR) to save millions of dollars in costs per year, transforming product returns into profit and improving margin

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