Author: Synchrono

  • How Johnstech Reduced Lead Times by 50%

    How Johnstech Reduced Lead Times by 50%

    The semiconductor industry is competitive, with efficiency and reliability being paramount for success. Johnstech International has consistently delivered results that surpass industry standards, most notably achieving a remarkable reduction in lead times to just 3-4 weeks, compared to the typical industry standard of 5-8 weeks. This achievement underscores their use of advanced planning, scheduling, and execution technology, setting a new benchmark for operational excellence. As manufacturers face the challenges of complex supply chains and market fluctuations, Johnstech’s approach over the last two decades stands out as a powerful example of how to optimize production and ensure timely delivery.

    testimonial from johnstech master scheduler

    The Challenge: Navigating a Volatile Market

    The semiconductor market is characterized by fluctuating demand and intricate production cycles. The global chip shortage during the pandemic amplified existing pressures, making on-time delivery a critical differentiator in the competition. For Johnstech, maintaining its position as a top-tier provider of test contactor solutions meant addressing several key operational hurdles:

    • Meeting Aggressive Deadlines: The industry standard for lead times can stretch from 5 to 8 weeks. Johnstech needed a system to consistently outperform this average.
    • Managing Complex Production: The nature of Johnstech products required a dynamic scheduling system capable of handling complex dependencies and priorities in real time.
    • Ensuring Visibility: A lack of real-time visibility across the production floor can lead to bottlenecks, delays, and inefficient resource allocation.

    To sustain growth and meet customer expectations, Johnstech required a solution that could synchronize its entire manufacturing environment, from the shop floor to the executive level. The goal was to build a resilient, demand-driven operation that could adapt to market shifts without sacrificing quality or speed.

    The Solution: Real-Time Visibility and Dynamic Planning and Scheduling

    Johnstech partnered with a leading technology provider renowned for its patented synchronization algorithm that revolutionizes manufacturing efficiency. This partnership enabled the implementation of a suite of powerful demand-driven software tools, including SyncManufacturing® and SyncView®. This strategic integration was designed to provide a cohesive, real-time view of the entire manufacturing ecosystem.

    Real-Time Planning and Execution with SyncManufacturing®

    SyncManufacturing® provided Johnstech with an advanced planning and scheduling (APS) system that synchronized and prioritized all critical resources. This system moves beyond traditional enterprise resource planning (ERP) RP limitations by offering a dynamic, real-time approach to production management. The software managed constraints and adapted fluidly to drive flow and ensure on-time production. Synchronizing the entire supply chain allowed Johnstech to manage priorities, status, equipment, and alerts with unparalleled precision. This capability was instrumental in optimizing workflows and minimizing idle time.

    Unprecedented Visibility with SyncView®

    Complementing the APS system, SyncView® created a real-time visual factory. This tool provided multi-enterprise visibility, keeping every level of the organization synchronized and informed. Decision-makers, planners, and operators gained access to live data on priorities, equipment status, and potential constraints. This level of transparency empowered teams to make proactive, data-driven decisions. Instead of reacting to disruptions, they could anticipate and mitigate them, keeping production schedules on track. The visual interface made complex data accessible and actionable for all stakeholders.

    The Results: Setting a New Industry Standard

    The implementation of this integrated software suite yielded transformative results for Johnstech, solidifying its reputation for reliability and performance. The data speaks for itself.

    Industry-Leading Times

    By optimizing every facet of its production process, Johnstech dramatically reduced its lead times. The company now consistently delivers complex, custom solutions in just 3 to 4 weeks, a stark contrast to the industry average of 5 to 8 weeks. This speed provides Johnstech and its customers with a significant competitive advantage, especially in a market struggling with the global chip shortage.

    Exceptional On-Time Delivery

    Another impressive outcome is Johnstech’s ability to surpass a on-time delivery goal of 95% and maintain a 98-99% on-time delivery rate. This near-perfect record is a direct result of the real-time synchronization and advanced planning capabilities of its new system. For customers in the semiconductor industry, where project timelines are rigid and delays are costly, this level of reliability is invaluable. It demonstrates a mastery of the supply chain and a deep commitment to customer success.

    Get the Full Story

    The Johnstech story is more than just a case of successful software implementation; it is a testament to the power of demand-driven manufacturing. By embracing real-time data and advanced planning and scheduling, the company has not only weathered the global chip shortage but also thrived. Their ability to deliver faster and more reliably than competitors offers a compelling model for any manufacturing leader aiming to optimize operations.

    To get the complete details of how Johnstech achieved these remarkable outcomes, download the full case study. Discover the specific strategies and technologies that enabled them to redefine performance in semiconductor testing.

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  • Advanced Cybersecurity: How NIST 800-171 Compliance Raises the Bar for Data Protection

    Advanced Cybersecurity: How NIST 800-171 Compliance Raises the Bar for Data Protection

    Cyberattacks are growing in frequency and sophistication, targeting organizations of every size and in every industry. For manufacturers that rely on digital systems to deliver products, support customers, and safeguard intellectual property, a single breach can trigger financial losses, downtime, and lasting damage to brand trust. As a result, cybersecurity has shifted from a back-office concern to a board-level priority. Choosing systems that adhere to well-established cybersecurity standards can provide peace of mind for the organization looking to entrust sensitive data to a new software vendor. 

    One of those standards is NIST 800-171. At Synchrono®, our adherence to this framework is a core part of our commitment to data security. While NIST 800-171 is mainly relevant for our customers who do business with government agencies, such as DOD, it can still serve as a powerful signal that the software vendor has implemented and defined verifiable security controls.

    In this post, we take a closer look at NIST 800-171 and how it applies not only to manufacturers supplying products to government agencies, but also to security-conscious organizations looking for a software platform to run sensitive, mission-critical processes. 

    What is NIST 800-171? 

    While NIST SP 800-171 is generally treated as a cybersecurity standard, the National Institute of Standards and Technology (NIST) categorizes it as a “Special Publication”, rather than a formal federal regulation. This publication defines a set of requirements for how Controlled Unclassified Information (CUI) and other sensitive but unclassified government information must be protected when it is stored, processed, or transmitted on external (non-federal) systems. These requirements apply to a wide range of entities, including contractors, suppliers, universities, and of course, software vendors, particularly those that deliver cloud-based services on behalf of U.S. government agencies.  

    Many U.S. government agencies, especially the Department of Defense, reference NIST 800-171 in their contracts and acquisition regulations.  In those cases, NIST 800-171 compliance is mandatory for the systems and environments where CUI resides, because the contract explicitly requires it. Therefore, a software vendor’s past work with government agencies does not necessarily indicate compliance with the standard.  

    developer concentrating on his computer in a workplace

    What kind of CUI data does SyncManufacturing® handle? 

    Controlled Unclassified Information (CUI) is a government acronym that refers to data that is not classified but is sensitive enough that it must be handled carefully and kept out of the public domain. For example, bills of material for defense components can inadvertently reveal details about weapon systems, aircraft, or other critical infrastructure. 

    Manufacturers that don’t do business with the government may also want to keep details about their products and processes out of the public domain to maintain a competitive advantage. Vendor and customer records, such as which subcontractors supply which parts, or which end customers receive which products, can also be sensitive information that could be misused in the event of a data breach.​ Synchrono treats this information with the same level of care, using NIST 800-171 control set as a guide for protecting both government and non-government sensitive data. 

    What are the NIST 800-171 requirements? 

    Although NIST 800-171 covers a broad range of government contract scenarios, many requirements apply directly to how a software vendor builds, operates, and supports its products and services. These requirements address areas such as user authentication, customer data storage and encryption, log capture and review, vulnerability management, and incident detection and reporting. Vendors are expected to enforce strong access controls within the application, encrypt data at rest and in transit, maintain detailed audit logs, and maintain a documented, tested incident response plan.  

    NIST 800-171 organizes these expectations into a set of control families that cover not only access control and encryption, but also areas such as security awareness and training, audit and accountability, configuration management, identification and authentication, system and communications protection, and incident response. Together, these families define how organizations should design, operate, and continuously improve the systems that handle sensitive information. 

    Some requirements also extend to the personnel and operational practices that sit “behind” the software. For example, vendors are generally expected to limit administrative access to a small group of authorized personnel, revoke access promptly when staff change roles, and provide ongoing security awareness training so employees understand their responsibilities in protecting sensitive information. 

    In addition to implementing these controls, organizations aligning with NIST 800-171 typically document how each requirement is addressed in a System Security Plan (SSP) and use a central tracking mechanism—often called a Plan of Actions and Milestones (POA&M)—to record gaps and remediation tasks. Approaching NIST 800-171 this way turns it from a one-time checklist into an ongoing security program, where controls are tested regularly, gaps are prioritized and closed, and evidence is kept current for customers, auditors, and, when applicable, government agencies. At Synchrono, NIST 800-171 compliance is not a one-time task—it’s a continuous commitment. We proactively adapt to updates and new releases, ensuring our controls are rigorously tested, any gaps are promptly addressed, and comprehensive evidence is maintained to meet the needs of our customers, auditors, and government agencies. 

    What the NIST 800-171 assessment process looks like 

    Organizations demonstrate adherence to NIST 800-171 through structured assessments that may be internal, customer-driven, or performed by independent assessors. Although the details can vary, the NIST 800-171 assessment process usually follows a standard flow. First, the organization defines the scope: systems, applications, and environments where CUI resides or is in transit. Next, an assessment compares existing controls against each NIST 800-171 requirement, documenting how those controls are implemented in a System Security Plan (SSP) and recording any gaps in a central tracking mechanism, often referred to as a Plan of Actions and Milestones (POA&M) or similar remediation register. Finally, the vendor closes any identified gaps, and a follow-up review validates alignment with the requirements.

    In the defense sector, NIST 800-171 assessments and scores are often recorded for the Department of Defense and serve as the foundation for Cybersecurity Maturity Model Certification (CMMC). In the defense sector, NIST 800-171 assessments and scores are often recorded for the Department of Defense and serve as the foundation for Cybersecurity Maturity Model Certification (CMMC). 

    Government-Grade Security for Every Business 

    Even for manufacturers that never touch government data, selecting software and services aligned to NIST 800-171 can significantly strengthen the overall security posture of the organization. The publication’s controls reflect widely accepted cybersecurity best practices, such as strong authentication, least-privilege access, continuous logging, vulnerability management, and incident response planning. In effect, adopting NIST 800-171-aligned solutions lends a mature, battle-tested security framework to commercial environments and streamlines vendor risk reviews.​ 

    While NIST 800-171 was built to protect sensitive government data, its security rigor can benefit any organization that manages mission-critical data and wants extra confidence when selecting a software partner.  

    If you have questions about how NIST 800-171 relates to your operations or how Synchrono® can support your security goals, contact our team to continue the conversation. 

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