
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.
One Plant’s “Go Green” Project
SOUTH AMERICAN MANUFACTURING FACILITY
- 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
Periodic Well Test Process
OIL EXPLORATION AND DRILLING COMPANY
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.
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.
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
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.
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.
Automotive Chemical Process and Parts
CHEMICAL PROCESS-AUTOMOTIVE
- The company reduced cycle time by a factor of 2
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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
Automatic Well Test Process
MANUFACTURING OIL & GAS
Circuit Simulation Optimization
ELECTRONICS, CONSUMER PRODUCTS AND OFFICE PRODUCTS
Crankshaft Production Failures
AUTOMOTIVE
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As a result of the process improvements, the company realized over $100,000 in annualized ROI (Return On Investment).
Data Cartridge Shell Molding
INJECTION MOLDING, HIGH-VOLUME MANUFACTURING
Decrease Mistakes and Improve the Cycle Time
FINANCIAL SERVICES
Drive Train Reliability – DFSS
LARGE EQUIPMENT MANUFACTURER
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Robust design changes that yielded a 13X improvement in reliability and a 10X cost reduction
GEMS Lightspeed ™ CT Scanner- DFSS
GE HEALTHCARE
- 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
High Variability in Titration Measurement System
ALUMINA REFINERY
Vehicle Out-of-Commission Rate
VEHICLE MAINTENANCE SUPPORT
TV Deflection Yoke – DFSS
ELECTRONICS COMPANY
Submersible Pump Production Process
MANUFACTURER – SUBMERSIBLE PUMP REPAIR
Increase throughput of the WSH Paint Booth
MANUFACTURER – PAINT OPERATION
Methyl Ethyl Ketone (MEK) Production Capacity & Variability Reduction
CHEMICAL INDUSTRY
Monoblock Duplexer upgrade – DFSS
ELECTRONICS COMPANY
Oil Content of Injection Water
OIL AND GAS COMPANY
Small Batch Blending Creates New Revenue – DFSS
CHEMICAL COMPANY
- 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
Photoreceptor Belt Tensioning System – DFSS
XEROX COMPANY
Product Forecasting Improvements
INTERNATIONAL SERVICES COMPANY
Water Treatment – Solids Reduction
WATER TREATMENT FACILITY