Manufacturing 2016-11-19T00:28:10+00:00

manufacturing case studies

We’re solving tough problems for hundreds of Industry, Healthcare and Government clients.

Pharmacist Information (PI) Outsert

PHARMACEUTICAL

A better and more cost effective method was required for applying the pharmacist information via shrink wrapping to a patient’s prescription.

  • $4 million in annualized ROI was created for the pharmaceutical company (after the cost of capital equipment)
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One Plant’s “Go Green” Project

SOUTH AMERICAN MANUFACTURING FACILITY

One Plant’s goals included using less power each year, taking advantage of sunlight and reducing water consumption.
  • annual electric power use dropped by over 1 million kilowatt hours resulting in savings of over $400,000 per year
  • water usage was reduced by over 75,000 liters per year
  • 400 employees arefully engaged and motivated to maintain these energy saving benefits
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Periodic Well Test Process

OIL EXPLORATION AND DRILLING COMPANY

Improve well test accuracy and capacity

ROI results:

  • $400,000 in better well work decisions and
  • $100,000 in the value of extra test capacity
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Response Time Project – “No Fluid Detected” Wells

OIL EXPLORATION AND DRILLING COMPANY

The organization’s response time to “No Fluid Detected” wells was impacting production and overall profitability.

  • $2,500,000 in annualized ROI was created for the Oil Exploration and Drilling company
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Decrease Cycle Time and Production Cost

ASSEMBLY

A leading manufacturer of medals, badges, and service ribbons for the Department of Defense and other federal agencies was experiencing phenomenal growth with a requirement to produce over a million parts per month.

  • Eliminated the need for a $100K capital improvement project
  • Recaptured 25% of existing space
  • Identified assembly cost savings of 20%
  • Overall ROI was a remarkable 1994%
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Improving Aircraft Engine Disassembly

AIRLINE

Turnaround time (TAT) for engine repair and overhaul was taking a business on the average of 62 days. The critical-to-quality (CTQ) was 45 days. The customers had to compensate for the poor TAT by having more engines in inventory. 

  • Variation in the cleaning and inspection process was reduced by 57%
  • Overall engine repair and overhaul TAT was reduced 37%
  • Inventory reduction and labor productivity increases produced nearly $6 million in savings
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Rejection Systems Used for Tracking Defective Materials

MEDICAL DEVICE MANUFACTURER

The problem/opportunity that this manufacturer was facing involved how to effectively combine two existing rejection systems used for tracking defective materials.

  • More than $118,000/year in incremental return on investment
  • Customers experienced higher quality
  • Improved quality-of-life for thousands of people worldwide
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Customer Service/Warranty Process Improvement

MACHINING, TOOLING, AND ASSEMBLY

The Customer Service/Warranty claims process was too cumbersome and costly. This was causing unnecessary cost to be incurred by the organization, but even worse it was creating an unsatisfactory experience for their customers.

  • The company realized over $100,000 in annualized ROI
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Automotive Chemical Process and Parts

CHEMICAL PROCESS-AUTOMOTIVE

A leading manufacturer of automotive parts was using a chemical absorption process. There was insufficient understanding of the key input factors controlling the chemical weight from this process with no predictive model available.  The current feasible solution was not optimum and had a Cpk of 0.40 and a defective rate of 23%.

 

  • The company reduced cycle time by a factor of 2
  • The control phase Cpk had improved to 1 with a 0.26% defective rate
  • The project met all goals with estimated future savings of $100,000
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Automatic Well Test Process

MANUFACTURING OIL & GAS

A major oil exploration and drilling company realized that improvements to their automatic well test processes were required to increase test accuracy and productivity.

 

  • The company realized $500,000 in annualized ROI
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Circuit Simulation Optimization

ELECTRONICS, CONSUMER PRODUCTS AND OFFICE PRODUCTS

The engineer desired a more effective way to optimize the circuit prior to building prototypes.

 

  • Circuit was designed faster and optimized significantly better than past designs, with significantly lower prototype costs
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Crankshaft Production Failures

AUTOMOTIVE

A major automotive company was experiencing excessive crankshaft production failures.

 

  • As a result of the process improvements, the company realized over $100,000 in annualized ROI (Return On Investment).
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Data Cartridge Shell Molding

INJECTION MOLDING, HIGH-VOLUME MANUFACTURING

Improve two significant defects in the molding of 8mm data cartridge shells.


 

  • Neither of these defects were ever found again for the life of the production of this product.
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Decrease Mistakes and Improve the Cycle Time

FINANCIAL SERVICES

Decrease mistakes and improve the cycle time for loan and lease applications.


 

  • Raised the first-time completion rate to 95%
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Drive Train Reliability – DFSS

LARGE EQUIPMENT MANUFACTURER

Drive Train Reliability – DFSS


 

  • Robust design changes that yielded a 13X improvement in reliability and a 10X cost reduction
     
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GEMS Lightspeed ™ CT Scanner- DFSS

GE HEALTHCARE

GEMS LightSpeed ™ CT Scanner – DFSS


 

  • Better image quality for earlier & more reliable diagnoses
  • Much faster scanning
  • Clinical productivity up 50%
  • 10x improvement in software reliability
  • Patient comfort improved with shorter exam time
  • Development time shortened by 2 years
  • Higher market share and significant profit margins
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High Variability in Titration Measurement System

ALUMINA REFINERY

High variability in titration measurement system


 

  • ROI (Return On Investment) benefits of $180,000
  • Indirect savings were also realized through increased productivity due to less maintenance problems caused by poor ratio control
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Vehicle Out-of-Commission Rate

VEHICLE MAINTENANCE SUPPORT

A vehicle maintenance organization was experiencing excessive time that vehicles were out of commission.


 

  • Improvements yielded $1.8 million in annualized ROI
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TV Deflection Yoke – DFSS

ELECTRONICS COMPANY

When embarking on a new design for a TV Deflection yoke, this electronics company looked to DFSS for its cycle time and robust design benefits.


 

  • Project yielded a $240,000 benefit in annualized ROI
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Submersible Pump Production Process

MANUFACTURER – SUBMERSIBLE PUMP REPAIR

The process to produce submersible pumps was too slow for a large manufacturer of these items. This was resulting in a large volume of lost sales and excessive costs.


 

  •  Reduced waste yielded $436,370
  •  Sales increases of $4.9 million.
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Increase throughput of the WSH Paint Booth

MANUFACTURER – PAINT OPERATION

Management wants to increase the capacity of the WSH paint booth by a sufficient amount to reduce the need for outside expenditures of more than $50,000.


 

  • net annualized savings of $115,236
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Methyl Ethyl Ketone (MEK) Production Capacity & Variability Reduction

CHEMICAL INDUSTRY

Methyl Ethyl Ketone (MEK) production capacity and variability reduction.


 

  • ROI including $100 million for MEK, $70 million for Ethanol and additional Soft savings of $25 million
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Monoblock Duplexer upgrade – DFSS

ELECTRONICS COMPANY

Rapid expansion of data and communications needs required this Electronics Company to undertake a major upgrade of its Monoblock Duplexer product line.


 

  • Project yielded a $724,000 benefit in ROI
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Oil Content of Injection Water

OIL AND GAS COMPANY

An oil exploration and drilling company needed to reduce the oil content of injection water and improve oil production.


 

  • Project yielded $800,000 in annualized ROI
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Small Batch Blending Creates New Revenue – DFSS

CHEMICAL COMPANY

The manufacture did not have the ability to accurately blend raw materials in small batch quantities and consequently the blended product was only sold in large batches of standard blends. When it was discovered that significant lost opportunities existed by not supplying smaller customized batches, a Design For Six Sigma (DFSS) team was assembled.


 

  • new revenue stream is projected to add over $50million in incremental revenue the first year
  • engineering costs have been reduced by over $200,000 annually
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Photoreceptor Belt Tensioning System – DFSS

XEROX COMPANY

When the current iGen3 was to be modified, the engineering team was tasked with redesigning the belt tensioning mechanism on the photoreceptor into a smaller package without adjusting the length of the belt.

 

The team met the performance and cost targets for this new design well within the expected timeframe. This new design enabled the next iteration of iGen3 to be delivered on schedule and meet the rigorous demands of the print industry customers.

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Product Forecasting Improvements

INTERNATIONAL SERVICES COMPANY

A study conducted showed that the accuracy of forecasts submitted to the product planning group was very low. As a result, the organization had serious problems with shipments and backlogs. Revenue targets were not being met.

 

As a result of this project, the service company received over $2 million in incremental revenue. In addition, forecast accuracy improvements have helped reduce inventory and simplify employee work processes.
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Water Treatment – Solids Reduction

WATER TREATMENT FACILITY

A Water Treatment facility measured their total solids to be 7 times the specification and treatment costs to be $.14 per barrel. Improvements were required to reduce this cost and bring water quality within required specifications.

 

  • yielded $854,000 in annualized RO
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