Zensar Technologies collaborated with a Fortune 500 manufacturing client to implement business intelligence and data warehousing solutions aimed at enhancing quality control processes across over 500 product lines. This engagement resulted in significant improvements, including a 3% reduction in costs associated with poor quality and substantial decreases in return rates. The success led to the client's recognition as one of the top 10 companies for global supply chain excellence in 2008.

1. Case Study: Driving Quality Control Processes for a Manufacturing
Client using Business Intelligence and Data Warehousing Solutions
Zensar Technologies Ltd.
Website: http://www.zensar.com
The Client
The client is a Fortune 500 company, and is the global leader in the manufacturing of networking
instruments that powers the internet.
The Business Challenge
The client’s Manufacturing Engineering Quality (MEQ) division faced the following challenges:
Implementing quality procedures for over 500 listed product lines that the client manufactures to
improve profitability & Customer satisfaction
Enforce strict compliance standards on their global suppliers.
Contribute in achieving an enterprise wide strategic initiative: ensure that the enterprise was
recognized by external experts as the undisputed leader in Supply Chain performance and
innovation. A parameter for the success of this initiative was AMR Research’s Top 25 Global Supply
Chain Companies rating.
The Engagement
The client is engaged with Zensar’s Business Intelligence & Data Warehousing Practice for creating BI
solutions that would fuel their Quality Data Infrastructure (QDI) and Quality Data Systems (QDS)
departments, responsible for providing all the information critical to making sound business decisions
by the MEQ. The engagement has scaled to include:
A team where the ratio of actual Client Employees to Zensar Resources is currently at 20:80.
The Client Employees focus on their core competencies of Analysis & Decision Making.
The Zensar Resources provide the entire operational framework for these departments.
The Solution
Zensar provided an end-to-end Business Intelligence & Data Warehousing solution that addresses
Business Requirements and at the same time, provides technical excellence and high cost efficiencies.
The solution comprises of:
Over 25 Dashboards comprising of quality metrics
Collecting Quality Metrics, in the three key areas of Manufacturing - Pre-Production Processes, In-
Production Processes, Post Production Processes
Maintenance and support to ensure 99.9% system availability for effective decision making.
A few of the dashboards created by Zensar provide visibility into:
Component DPMO (Defect per million output): Provides visibility into component DPMO by commodity
groups
CPAT (Corrective, Preventive Action Tool): Provides Line Stops, Stop Ships, Mfg Alerts, P1, P2 and P3
corrective metrics
Engineering Change Management: Provides foundational cross product visibility into metrics which will help
drive an effective and consistent engineering change management process.
Production Yields: Provides visibility into PCAs (Printed Circuit with low ICT (In circuit tests) & functional ETE
(end to end) production yields
Supplier Quality: Provides Supplier and Component quality metrics

2. Case Study: Driving Quality Control Processes for a Manufacturing
Client using Business Intelligence and Data Warehousing Solutions
Zensar Technologies Ltd.
Website: http://www.zensar.com
Business Benefits
The following are a few of the overall business benefits that the client has accrued since the initiation
of the engagement:
Technology Expertise
For this engagement, Zensar deployed a team of experts with extensive experience and expertise in
the following Business Intelligence technologies:
• ETL Tool - Informatica 7.1
• Database – Oracle 9.1
• BI Tools - Siebel Analytics 7.8, Business Objects 6.x
• Microsoft Visual Source Safe (Version Control), Unix Shell Scripts
• Scheduler - $U
Profitability:
• A 3% reduction in the cost of poor field quality and a 1.1% reduction in the cost of poor quality due
to failures during production, over 2 years, amounting to substantial actual savings in cost.
• An approximate 28% reduction in Time Based Product Returns (for products returned between the
7th
and 18th
month post sale to the final customers) in the past 1 year.
• An approximate 40% reduction in the Time Based Product Returns (for products returned between
the first 6 months post sale to the final customers) in the past 1 year.
Achievement of Corporate Goals
• A rank within the Top 10 companies for Global Supply Chain excellence in AMR Research’s Supply
Chain Top 25 in 2008.
A Unique Business & Information Technology Collaboration Model
• Zensar provided a unique team, comprising not only of technology experts, but Business Analysts as
well to perform the end-to-end operational functioning of the quality data infrastructure and systems
divisions, leaving the high level decision making for the client’s employees.