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Case Study

Case Study. Quality Control Lab Kaizen Event. Goals Reduce inventory 25% Improve productivity 25% Create Standard Operations September 15- 19, 2005. Baseline Metric: People Flow. 320 ft worth of movement !!. Takt Time Chart. Takt Time = 620 minutes = 525 seconds

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Case Study

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  1. Case Study Quality Control Lab Kaizen Event • Goals • Reduce inventory 25% • Improve productivity 25% • Create Standard Operations • September 15- 19, 2005

  2. Baseline Metric: People Flow 320 ft worth of movement !!

  3. Takt Time Chart Takt Time = 620 minutes = 525 seconds 71 Tests

  4. Trial Setup Instron Denier T.S. Coherency Operator One Operator Two WIP WIP WIP WIP Exit Material Flow Operator 3

  5. Before Layout New Cellular Layout

  6. Summary of Achievement Goal is 71

  7. Trial Results TAKT TIME Computer issues disrupt ability to meet Takt Time

  8. Six Sigma: Reducing Variation • Network too slow • Re-Test procedure causing extra tests • Eliminated unnecessary test • Mistake-proofed sample log screens • Coached adherence to standard operations across all four shifts • Separated log screens to minimize file open/close time Achieved Target of 71 Tests!

  9. Case Study Sigma Kaizen EventReduce Fray Defects by 50% March 28 – April 2, 2005

  10. Charter Defined defect as broken filament High level process map Detailed Quality Map Gage R & R on measurement systems Fish bone diagram to determine cause and effect Difficulty impact matrix Process Capability Comparative Analysis Define and Measure

  11. Repeatability Visual Inspection Gage R & R Results Within Appraisers Assessment Agreement Appraiser # Inspected # Matched Percent 95 % CI Brenda 32 25 78.13 (60.03, 90.72) Vic 32 23 71.88 (53.25, 86.25) Chris 32 23 71.88 (53.25, 86.25) Katrina 32 24 75.00 (56.60, 88.54) Edgar 32 24 75.00 (56.60, 88.54) Sue 32 10 31.25 (16.12, 50.01) # Matched: Appraiser agrees with him/herself across trials Reproducibility Between Appraisers Assessment Agreement # Inspected # Matched Percent 95 % CI 32 7 21.88 (9.28, 39.97) # Matched: All appraisers' assessments agree with each other. Goal should be > 90% correct decisions!

  12. Visual Inspection Gage R & R Results • No operators met the gage R&R goal of 90% • Visual expert was only 62% repeatable! • Completed parallel study using automated defect counter • Gage results met 90% goal Through MSA, determined good product was labeled defective.

  13. DMAIC at Kaizen Speed Project Charter to Implementation completed in 6 weeks! Kaizen Team process helps buy-in and sustainment 9 to 12 months Traditional Black Belt Project Kaizen 6 weeks Improved yield 2.5%!

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