The production of highly precise computers required a large level of training for operators within the production team.
We designed a training program that vastly reduced the training time to enable production to ramp up without delays.
Reduction in non-conformances
Savings per year
Working closely with a Tier 1 Automotive supplier that manufacturers plastic injection moulded components, we commenced our work with the assessment phase.
As part of our benchmarking process, we identified that the number of non-conformances within the quality control process was far above what similar companies were achieving.
Upon further inspection we pin-pointed the problem down to the lack of standards with a particular machine. Alongside 5 other initiatives, we decided the first project should be focused on quality. Identifying deviations as soon as possible and wherever possible, preventing defects from being produced.
Working as one team, in workshop style. We were able to find the root cause, brainstorm solutions, test them and finalise a permanent solution all in one week. By redesigning the process for sonic welding with the operators themselves, we implemented new standards that the team took ownership of.
The result of the first phase of the project was a reduction in non-confances by over 90%. This equated to a reduction in scrap and rework of over £500k per year.