Goals

1. Reduce inventory 25%

2. Improve productivity 25%

3. Create Standard Operations

September 15- 19, 2005

Quality Control Lab

Kaizen Event

Baseline Metric: People Flow

320 ft worth of movement !!

Takt Time Chart

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100

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300

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500

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Denier Instron Coherency Thermal Shrinkage

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Manual

Auto

Takt Time = 620 minutes = 525 seconds 71 Tests

Trial Setup

Denier

Coherency

Instron

T.S.

WIPWIPWIPWIP

Material FlowExit

Operator OneOperator Two

Operator 3

New Cellular Layout

Before Layout

Summary of AchievementMeasure Before After Improvement

Operators per Shift 5 4 20%

Inventory 65 34 42%

Movement per Test 320 ft 60 ft 81%

Tests per Shift 42 61 31%

Equipment Used 14 10 29%

Material Flow Intersecting, colliding

One direction, flow

Goal is 71

Trial Results

0

2

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14

Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7 Test 8

Min

ute

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Above Takt Time- Computer issue

Above Takt Time- Computer issue

Computer issues disrupt ability to meet Takt Time

TAKT TIME

Six Sigma: Reducing Variation• Network too slow• Re-Test procedure causing extra tests• Eliminated unnecessary test• Mistake-proofed sample log screens • Coached adherence to standard operations

across all four shifts• Separated log screens to minimize file

open/close time

Achieved Target of 71 Tests!

Sigma Kaizen Event

Reduce Fray Defects by 50%

March 28 – April 2, 2005

Define and Measure

CharterDefined defect as

broken filamentHigh level process

mapDetailed Quality MapGage R & R on

measurement systems

Fish bone diagram to determine cause and effect

Difficulty impact matrix

Process CapabilityComparative Analysis

Visual Inspection Gage R & R ResultsWithin Appraisers

Assessment Agreement

Appraiser # Inspected # Matched Percent 95 % CIBrenda 32 25 78.13 (60.03, 90.72)Vic 32 23 71.88 (53.25, 86.25)Chris 32 23 71.88 (53.25, 86.25)Katrina 32 24 75.00 (56.60, 88.54)Edgar 32 24 75.00 (56.60, 88.54)Sue 32 10 31.25 (16.12, 50.01)

# Matched: Appraiser agrees with him/herself across trials

Repeatability

Goal should be > 90% correct decisions!

Between Appraisers

Assessment Agreement

# Inspected # Matched Percent 95 % CI 32 7 21.88 (9.28, 39.97)

# Matched: All appraisers' assessments agree with each other.

Reproducibility

Visual Inspection Gage R & R Results

• No operators met the gage R&R goal of 90%

• Visual expert was only 62% repeatable!

• Completed parallel study using automated defect counter

• Gage results met 90% goal

Through MSA, determined good product was labeled defective.

DMAIC at Kaizen Speed

Project Charter to Implementation completed in 6 weeks!

Kaizen Team process helps buy-in and sustainment

Improved yield 2.5%!

Traditional Black Belt ProjectKaizen

9 to 12 months

6 weeks