Benchmarks & Client Cases
Quality Improvement in Discrete Assembly
• Over $200,000 cost of non-quality parts per year
• 744 hours dedicated to reworking each year
• High variability across the assembly tasks, resulting in outputs of differing qualities
• Ad-hoc resolution of non-quality incidents, with no permanent countermeasures being incorporated into the responsible process
• Lack of visibility of all the non-quality problems and their root causes
• Implementation of a control & detection system to identify non-quality incidents as soon as they occur and mitigate them - non-quality matrix
• Development of structured problem-solving capabilities at team leader and group leader levels
• Development of a "stop scrap" system that allows for the sustainability of the quality improvement activities
• 105 3C initiatives concluded in an effort to solve minor quality causes
The project had a payback period of 3 months with annual savings surpassing $307,000.
Cost of non-quality parts reduced by 51%
Hours of rework
Hours of rework required to correct non-quality issues reduced by 33%
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