| PROBLEM SOLVING | ||||
| Customer: | Power Tools manufacturer | |||
| Need: | Produce a new product similar to an current production | |
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| casting with significantly reduced internal and customer | ||||
| ppm levels due to leaks and porosity. | ||||
| Solution Process: | Customer line return ppm target was set. | |||
| Internal ppm and line rate target were set to achieve | ||||
| customer levels. | ||||
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| A problem solving team was set up and given clear targets. | ||||
| Data was collected and Pareto charts completed to reveal | ||||
| the key contributors to the inefficiencies. | ||||
| A Six Sigma Quality Plan was presented to the customer | ||||
| and approved. Actions and follow-ups were completed until | ||||
| root causes were offset with permanent solutions. | ||||
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| Results: | Both a written and visual standard was created with the | |||
| customer to establish acceptance criteria for surface | ||||
| porosity. | ||||
| Permanent solutions were implemented in the process | ||||
| which included such items as: improved machined | ||||
| maintenance plan, revised control plan and gages, and | ||||
| increased operator training. | |
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| As a result of an approximately 40% improvement in first | ||||
| time leak rates overall quality to the customer was improved | ||||
| and line rates achieved to standards targeted. | ||||
| Division: | Atlantic | |||