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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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