MFG DAY 2014: Stories about Overcoming Top Manufacturing Challenges

Founded on June 26, 2012, MFG DAY is a non-profit organization dedicated to addressing “common misperceptions about manufacturing by giving manufacturers an opportunity to open their doors and show, in a coordinated effort, what manufacturing is – and what it isn’t.” Today, there are more than 1,500 national events on October 3rd from Washington D.C. all the way to Hawaii. MFG DAY has become a movement that has helped build transparency between manufacturers and consumers.

In honor of MFG DAY, we have compiled a few stories that highlight our clients’ success in overcoming some of their toughest manufacturing obstacles.

Snak King
Reduced product waste by over $1 million
Snak King, a snack food manufacturer, identified variability in their quality procedures that resulted in inconsistent product quality and waste. Snak King’s goal was to implement an SPC solution that could help them produce a consistently high-quality product. Using InfinityQS ProFicient, Snak King was able to identity process variability and reengineer the process to improve product quality. Snak King also tracks incoming receiving and customer complaints using InfinityQS. 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.

Reduced warranty claims by 48%
Baldor Electric Company, a manufacturer of industrial electric motors, power transmission products, drives and generators, implemented an initiative to improve customer satisfaction through improved product quality, Critical to this initiative was improvement in product quality, production and inspection time, and reduced defects.  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. Ultimately Baldor achieved a 13% reduction in overall scrap costs and an impressive 48% reduction in warranty claims, reflecting superior customer satisfaction.

Gained total quality management with “Best of Breed” approach
SanDisk, a manufacturer of flash memory cards and components for consumer electronics, had factory Manufacturing Execution (MES) and Quality Management Systems (QMS) in place, but neither provided the granular, real-time process data at the shop floor level needed to ensure quality consistency throughout production. Rather than customize their in-place MES solution, SanDisk identified InfinityQS ProFicient as a powerful quality management solution that integrates with their existing system infrastructure. As a result, SanDisk’s quality and process control team gained a closed-loop solution that can place a hold on a lot through the MES, send notifications and alerts and create quality incidents via QMS. SanDisk was also able to consolidate and standardize live production data for analysis and control. Ultimately this allowed the SanDisk team to act on every potential incident preventing the manufacture of defective products resulting in a significant cost savings.

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