Benchmarks & Client Cases 

Quality Improvement in Discrete Assembly

The Challenge

 

improvement-implementation-plan

Problem


• Over $200,000 cost of non-quality parts per year

• 744 hours dedicated to reworking each year



Root Causes


• 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

The Solution

structured-problem-solving 

• 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 Results

The project had a payback period of 3 months with annual savings surpassing $307,000.


non-quality-cost-benefit

Non-quality cost

Cost of non-quality parts reduced by 51%

hours-rework-benefit

Hours of rework

Hours of rework required to correct non-quality issues reduced by 33%



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