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Specialty Metals Industry:
Six Sigma / Manufacturing Productivity
Improvement
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Client: |
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A major specialty
chemical manufacturing company globally supplying a vital component
to the electronics industry.
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Problem: |
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Need to increase
product output 15-25% within 9 months to keep pace with electronic
industry demands and to increase market position. Need to increase
process yields, improve quality, and reduce cycle time of key processes.
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Approach: |
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Using a Six Sigma
and team-based methodology, defined specific task objectives, developed
annual, monthly, weekly, and daily performance targets and metrics.
Identified process bottlenecks and sources of variation and risk.
Trained problem-solving teams and team leaders in each of the key
process areas in team process, statistical process control, and the
structured problem-solving process. Trained and mentored management
in leading/supporting improvement efforts. Defined strategy and tactics
to remove barriers to success and improve process performance.
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Results:
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Met and exceeded
client needs and expectations. Increased product output by 33% within
6-9 months allowing client to maintain market position, meet customer
requirements, and build upon foundation for future growth and development.
Increased manufacturing capability an average of over 30% and process
yields 50% through process improvement, process management, in-process
metrics, manufacturing support, attention to detail, and technical
improvements contributing $12 Million to the bottom line. Defined
plans for additional 2-3 fold increases in output over the next 1-2
years. Began the transformation of client skills and abilities to
a data-driven, problem-solving environment. Created a client recognition
that we are “the first consultants that they ever met that did what
we said we would do and actually rolled up our sleeves and accomplished
what needed to be done!”
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