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