OEE Improvement and Defects Reduction through Lean Six Sigma

OEE Improvement And Defects Reduction Through Lean Six Sigma
A large multinational group having a major confectionary unit in South India. Cultural change, data based thinking, Poor maintenance..The average OEE of the continuous lines was at 45% and scrap and rework level was at 9%
Poor maintenance and increased scrap levels had driven staff / operators morale to very low levels. Involved all the concerned on the shop floor in solution generation and SPC implementation through Kaizen / CFT working /
OEE improvement and defects reduction through lean Six sigma

Client:

A large multinational organization in the field of household insecticides and air care products.
Challenge:

Cultural change, data based thinking, Poor maintenance..The average OEE of the continuous lines was at 45% and scrap and rework level was at 9%
Project:

To improve the OEE from 45 to 60% and reduce the defect level by 30%
Approach:

Use blended approach of Lean Six sigma / DMAIC approlach and statistical process control alongwith TPM tools
Activities:

process mapping and capability analysis, introduction of DMAIC approach and 9 step process for OEE improvement , Basic 7 QC tools and Statistical process control
Results and financial returns:

:: Overall scrap reduction from 9 % to 6.5%
:: Average OEE improvement from 45% to 65%
:: Approx cost reduction of Rs. 1.1.crore per annum
What makes this a “Lean Six Sigma” project?

::Focus on reducing the number of defects found by customers and internal defects
:: Intensive use of process metrics and quantitative methods
:: Introduction of new review techniques to improve defect containment
The Lean Six sigma toolkit:

Process mapping techniques, Process capability analysis and metrics, Basic seven QC tools ,OEE tracking, TPM AM / PM practices, hypothesis testing and regression analysis, Statistical Process Control (SPC)
How did we engage people and drive change?

Poor maintenance and increased scrap levels had driven staff / operators morale to very low levels. Involved all the concerned on the shop floor in solution generation and SPC implementation through Kaizen / CFT working /.
Gazelles added value:

Extensive experience in Manufacturing Process Improvement initiatives and the ability to effectively teach more advanced

Share this post

Related Posts