Performance Management
We resolve operating system gaps
Manage a critical launch, new product new technology
For industry: Tier 1 Truck emission control systems
Project Challenge
Start up didn’t produce the Customer required quantity and rework level was a major challenge due to the high complexity.
Strategy Applied
Strategic problem solving for the top offenders using Shainin Red X complemented by Yellow Belt / A3 at each station, to resolve line stops.
Develop technology concept to significantly reduce rework time.
Introduction of Statistical Process Control per station to reduce process variation.
Implemented Results
FTQ (% of good parts produced ) improved from 0 to 50%, on plan to 70%.
Average rework time from 5h/part to below 15’.
Bottlenecks eliminated, no further delivery issue to Customer.
Reviewed Project Development Plan to identify and resolve root causes to enable future flawless launches.