November 18, 2014
Quality Challenge #2: Delayed Improvement Cycles
In today’s competitive manufacturing landscape it is important to focus quality efforts and make measured improvements that will boost your processes. But do you know where to start? Oftentimes, decision makers lack the real-time visibility they need to pinpoint the areas that are in need of the most improvement.
- Incorrect or missing information makes it impossible to prioritize actions
- Separate systems and databases make it harder to aggregate data and compare results
- Inability to compare metrics across shifts, lines, parts, etc. results in poor analytics and a lack of a baseline
How can you decide where to apply your resources when you lack the big-picture view into your processes?
Blueprint: The first step
Capturing and centrally storing data from multiple sources are the first steps to identifying areas of improvement as aggregated data provides a complete view of all your processes. However, the key to continuous improvement is the ability to leverage that data by visualizing it in real-time charts and reports that you can use to make necessary changes to your processes. Having a big-picture view of your operations provides the manufacturing intelligence necessary to begin making decisions to improve quality and reduce scrap and rework, ultimately saving you money.
Real Problems, Real Results
Baldor | Secondary Challenge: Incomplete Plant View
Reduced Warranty Claims by 48%
The management of Baldor Electric Company, a manufacturer of industrial electric motors, power transmission products, drives and generators, faced the challenge of involving all employees in their continuous quality improvement efforts. To meet this challenge Baldor’s objectives were to improve gauging measurement and accuracy, decrease production cycle times, lower the cost of scrap and make faster and more accurate inspections. To accomplish these objectives Baldor instituted statistical process control (SPC) via InfinityQS ProFicient software into the corporate culture. Using ProFicient, quality personnel, engineers and managers all monitor and analyze quality data around the clock to make process improvements as needed. Utilizing the ProFicient software enabled Baldor to create and share SPC charts so all employees could analyze and make improvements through data- driven quality decisions. It also eliminated hand-written charts and logs, significantly improving inspection accuracy and speed. Ultimately Baldor achieved a 13% reduction in overall scrap costs and an impressive 48% reduction in warranty claims.
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Snak King | Secondary Challenge: Incomplete Plant View
Reduced Product Waste by Over $1 Million
Snak King, a snack food manufacturer, realized there was variability in their quality procedures because they were not using true statistical process control (SPC) decision making rules. This caused inconsistent product quality and waste. Snak King’s goal was to implement an SPC solution that could help them produce consistently high-quality products. Using InfinityQS ProFicient allowed Snak King to see process variability so they could reengineer the process to improve product quality and freshness. Snak King also tracks incoming customer complaints using InfinityQS, gaining insights into specific geographical areas where additional quality steps should be taken. Improvements in product consistency resulted in over $1 million in reduced product waste in the first year alone and a 30% improvement in customer complaints.
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Accellent | Secondary Challenges: Incomplete Plant View; Overwhelmed Shop Floor
Reduced Inspection Times by 80%
As the leading contract manufacturer of medical devices in the cardiology, endoscopy and orthopedic markets, Accellent focused on eliminating customer complaints through continuous improvement. InfinityQS ProFicient provided Accellent the visibility to identify and resolve process issues in real time while custom alerts enabled operators to make on-the-spot adjustments to prevent the production of non-conforming parts. In addition to significant cost savings, these extra layers of security have reduced the risk of recalls and customer complaints. Furthermore, the integration of inspection automation to collect data during incoming and final inspections has reduced source inspection times by 80% while the feature that allows engineers to put “any data on any chart,” boosted Accellent’s ability to measure and analyze production processes.
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