Projects

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Projects2019-07-29T13:31:14+00:00

Extracts from Six Sigma Projects

  • Scrap reduction in the production of antishock dampers
  • Process optimisation for the finishing of galvanic parts of the chassis
  • Reduction of multiple EOL tests for front axis parts
  • Reduction of the „non value adding“ work with n.o.k.- parts of a driving chain
  • Reduction of wire breaks and optimisation of the winding parameters
  • Rework reduction for rotation dampers
  • Scrap reduction at a hydraulic assembly of chassis parts
  • Task Force project for dampers in cooperation with 5 suppliers
  • Reduction of scrap costs in the mechanical chipping of truck operating parts
  • Analysis of the „Cost-Price-relationship“ of sinter parts
  • Optimisation of „delivery on time“
  • Optimisation of the adjustment steps at a Front production
  • Productivity increase (Automotive Business)
  • Increase of the amount of „Good pieces“ and optimisation of the primary check of the mass production of hydraulic chassis parts
  • Optimisation of „SOP“ of the mass production of hydraulic chassis parts
  • Process optimisation of plastic laserwelding
  • Optimisation of the plastic injection process for automotive internal door furnishings
  • Optimisation of the plastic injection process for the automotive internal dashboard fittings
  • Reduction of defects within the injection process (contact systems)
  • Reduction of time offset within the injection process (contact systems)
  • Reduction of stock of a large scale production for hydraulic gear compontents
  • Reduction of damage of shockabsorbers within automotive transportation
  • Reduction of stock (systematic analysis of the root causes for excess stock and low stock turnover within multiple projects)
  • Optimisation of the provision of trains
  • Reduction of scrap and inventory cost
  • Error rate reduction in the drill production
  • Reduce scrap costs of hydraulic sub-assemblies
  • Leaking AL- component after the laser welding
  • Waste reduction and productivity improvement in a hydraulic assembly
  • Reduction of defect costs for the laser welding process
  • Increasing the application rate of a pipe cutting machine
  • Increasing productivity in the production of digital cameras *
  • Increased productivity of a welding centre
  • Waste reduction module assembly
  • Optimizing the cycle time of a calendar
  • Complexity reduction of generator rotors
  • Optimizing planning processes in plant
  • Throughout optimization in chemical plants
  • Optimization of a plastic injection moulding machine for automotive interior fittings
  • Increase on-time delivery and availability of materials for equipment installation
  • Cost reduction in doors of smokers
  • Optimization of the return process of electronic spare parts
  • Reduction of rework in the commissioning of new plants
  • Optimization of the cycle time for laser welding systems
  • Mislabelled components
  • Density of channels with gas filling
  • Reduction failure rates of high-frequency generators
  • Life cycle in high-frequency generators: Preventive Service
  • Reducing warranty costs for laser cutting machines
  • Improvement of the security of supply of raw materials
  • Reduction of delivery risks from a small number of suppliers of raw material
  • Shortening lead times (focus: material income, QA and production approvals for recipes)
  • Reduction of the number of change orders and credits
  • Increased productivity by reducing the interference
  • Reducing downtimes to plant xy
  • Waste reduction
  • Reducing lead time of bulk products
  • Increased performance of washing equipment
  • Reduce disposal costs and yield losses
  • Reducing lead time of reporting and releases
  • Reduction of rework to ensure the quality of mixtures
  • Optimizing the use of cork grinding flour for the production of floor coverings
  • Optimization of scrap of mixing
  • Optimization of disposal processes
  • Optimize energy management and water heating
  • Paper, cardboard and paper processing
  • Reduction of intermittent downtimes on board shaping machine
  • Reduction of scrap compound coating
  • Reducing PE edge trimming
  • Reduction of scrap at roller
  • Enhance productivity at COEX systems
  • Reducing solvent consumption
  • Reduction of rejects
  • Reducing inventories of raw materials / RF and finished goods
  • Optimization of the development process for a manufacturer of high quality watches
  • Optimization the usage of space in a development centre
  • Shorten the processing time of VV ‘s in the employee improvement programme
  • Optimization of space usage
  • Optimization dispatch process
  • Optimization package delivery service process
  • Relocation of production to a new plant
  • Engineering and relocation of an entire branch of production
  • Rough cost estimate process optimization factory planning
  • Optimization of the application process
  • Lean Action Workout (LAW) for immediate implementation of the improvements in the main processes
  • Reduction of call volumes
  • Change Management (IT Changes)
  • Appropriate service level agreements in the field of technical services
  • Reduction of service costs (logistics IT spare parts)
  • Appropriate Service Level Agreements (SLA’s) in the field of technical services
  • Increased sales efficiency (sales of IT services)
  • Shortening lead times and reduce costs in repair processes
  • Optimization of the service process in an amusement park
  • Optimization of a call centre staffing at an amusement park (depending on incoming customer calls)
  • Increasing the booking probability for new customers at an amusement park
  • Optimization of maintenance at an amusement park
  • Optimization of the goods sold at an amusement park
  • Increase customer satisfaction at the buffet at an amusement park
  • Improvement of the House -keeping process in an amusement park
  • Optimization of the property planning at an amusement park
  • Optimization of the repair process in Supply Operations
  • Package audit process optimization package service process
  • Evaluation of the reliability of the repair data entry
  • Optimization complaint process in Operations
  • Inventory Optimization (systematic analysis of the causes of excessive inventories and low turnover (on a number of projects)
  • Optimization of air freight costs

Extracts from Design for Six Sigma Projects

  • Design of electrical components for the driving chassis
  • Design of a new application for chassis damping
  • Design of a standardised spring seat
  • Design of a guiding unit for a sealing
  • Development of a new painting lacquer
  • Impeller for cooling liquids
  • Air management
  • Air-water-management
  • Production machine for insulating plates
  • Gap – Designs for cars (2 projects)
  • Fuel cells for Automotive production
  • Smoothness of Interieur-foam parts
  • Batteries for Eco friendly cars
  • Electrical car control (noise issues)
  • Roof moduls of cars
  • Amplitude sensitive dampers (ASD)
  • Leakage rear moduls
  • Noise levels of external mirrors at cars
  • Luggage compartment – Roller curtain
  • Chassis assemblies (Reliability, preloading forces)
  • Systematic development of different design concepts (Axiomatic Design)
  • Preventive review of the concepts in terms of functionality, complexity, risks and costs
  • Detailed process design for the selected concept
  • Development of relevant (hypothetical) process transfer functions
  • Planning and carrying out the necessary tests
  • Data analysis for the detection of the transfer functions
  • Focusing on the coating process
  • Setting, definition and implementation of appropriate metrics
  • Determination of verified causes
  • Determining the optimal settings
  • Minimize risks
  • Determination of required tests, SPC – points, sample size
  • Systematic quantification of the risks in a fully automated packaging line
  • Derivation, definition and implementation of appropriate metrics
  • Determination of verified causes
  • Determining the predominant defect mechanisms
  • Preventive actions striving for a lean design
  • Development and implementation of a communication board for production
  • Application of tools in research and development of chemical products and processes
  • Axiomatic design (development of functional and physical structures, calculate the information content of styles, linkage analysis)
  • Systematic generation of concepts
  • Functional analysis
  • Systematic use of “white spots” in research
  • Systematic evaluation and selection of chemical design concepts
  • Integration of Data Mining and Text Mining
  • Use of tools in the development of chemical processes
  • Continuation of the causal chain from product to process design using “Axiomatic Design”
  • Design of experiments and simulations DoE
  • Tolerances in chemistry
  • Development of an appropriate sampling method for attribute features in the food industry
  • Structure of the causal chain of customer requirements for product and process characteristics
  • Development of a generally applicable method for calculating sample size – and frequency
  • Linking sample sizes, attributive capability indexes, the reliability of test and measurement systems and the risk considerations in FMEAs
  • Focusing preventive examinations
  • Implementation of an interface to information and communication system
  • Development of a tailored IT support

Project “Management Control & Reporting – System”

  • Systematic analysis and optimization of Management Control & Reporting System (MCRS)
  • Flow of information and communication
  • Control loops in terms of schedule, cost and quality
  • Documents to support MCRS
  • Evaluation of existing indicators, lack of key indicators
  • Isolated activities
  • “Top -down ” planning and “bottom up” – reporting
  • Measure the actual system for an area with about 1200 employees
  • Analysis of the interaction between sales, development, planning, purchasing, production areas with multiple Key departments, QM, logistics
  • Development of a “Brown Paper” for the presentation and analysis of the system with all actual documents and IT systems
  • Analysis of media consistency
  • Gradual development of a suitable and preventative target system with appropriate indicators
  • System development with a focus on causality between the ratios
  • Assessment of the actual system for a complex development area
  • Analysis of the interaction of sales, various development departments, laboratories, scheduling, purchasing, suppliers, QM, logistics
  • Development of a “Brown Paper “for the presentation and analysis of the system with all actual documents and IT systems
  • Analysis of the current system
  • Setting of short / long- term measurements to improve the system
  • System development with a focus on causality between the metrics and supports the implementation