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SUPPLIER QUALITY PROJECT

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Project summary

Situation
  • ​New motor supplier
  • High electrical motor failures for "weak/slow".
TASK
  • Improve motor performance from supplier.​
ACTIONS
  1. Visit supplier in China
  2. Walk process and understand complexity (Gemba)
  3. Brainstorm product and process
  4. Train & develop supplier in Quality tools/methodology
  5. Conduct DOE to find the bigest contributing factors
  6. Control shaft straightness (SPC & Capability)
  7. Increase carbon brush spring force (Capability)
  8. Introduce inline coil windings resistance check
RESULTS
  • Motor speed increased by +200 RPM (13% increase)
  • Zero Defects at customer (monitored & confirmed for 1yr period)
  • Saved £40K and No disruption at the customer

WARRANTY
​COST REDUCTIONS

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Project summary

Situation
  • £1.5 mil / yr customer world wide warranty charges
TASK
  • Understand warranty claims and review liability
  • Reduce warranty costs
ACTIONS
  1. Analyse warranty claims
  2. Review actual parts
  3. Fully understand Customer T&C's
  4. Reject claims were not liable
  5. Rank / Pareto liable failures
  6. Understand B10 life failure rate for top claim
  7. Improve design of product 
  8. Confirm reliability by inducement testing (Weibull analysis)
  9. introduce modification
RESULTS
  • £500k of claims rejected back to customer
  • Design change long term reduction awaiting data
  • Ongoing project, monitored monthly & quarter
  • 6yr project, current data, actual scrap cost / yr. is £180k (£1.3 mil or 88% total saving)

​WASTE SCRAP COST REDUCTIONS

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Project summary

Situation
  • £5 mil / yr scrap costs
TASK
  • Define what and where the top contributing reasons for the scrap
  • Reduce scrap costs.
ACTIONS
  1. Rank / Pareto failures
  2. 40% of the failures were surface defects (£2 mil)
  3. Confirm/reject failures by aligning customer & in-house standards
  4. Set & standardise all surface defect failure types
  5. Train and verify all staff to the standards (GR&R)
  6. Improve handing of parts (gloves / packaging in house and at the suppliers)
  7. Change assembly jigs & nest design and materials (soft inserts)
RESULTS
  • 75% reduction of the surface defects
  • £1.5 mil scrap cost saving (1st project saving)
  • Ongoing project, monitored weekly & monthly
  • 5yr project, current data, actual scrap cost / year is £250k (£4.5 mil or 95% total saving)
Initial consultation is discussed on your site or via a web link to establish 'voice of the customer' and understand what support you need.

> Take advantage of our free one day audit to highlight potential business improvement opportunities.
> Support for existing projects to ensure a robust closure.
> Deep dive support for a new lean system introduction.
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​Our passion is your success; ​we make your vision a reality​.


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44 Mansfield Road
Worksop,
S80 3AD

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dave@industryleansolutions.com
07757 697979​

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pete@industryleansolutions.com
​
07485 682023

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​​​All rights reserved.

A ​Registered Company: 12824200
Website designed and maintained by T5DESIGN
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  • Home
  • TRAINING
    • Introduction to Lean Six Sigma
    • Six Sigma Belts
    • Case Studies Training
  • CONSULTING
    • Case Studies Consulting
  • CONTACT