During the study, a significant amount of scrap was observed. Using Management Tools the reasons for scrap was discovered. The processes used were brainstorming, cause & effect analysis and pareto analysis. Integrated data was collated from:
- production line / machine run data
- order requirement information
- employee evaluations
- work instruction training performance
Methodology: Seven bobbins were loaded on the stabilizing line at a time to form a seven ply strand. All the seven bobbins have to be filled to the same length. If the bobbins do not have the same length of wire filled, then many rings are left over resulting in scrap.
High quality processes deliver high quality products, at the lowest possible cost and on time. By making certain minor changes in the existing process it can yield great benefits in terms of money. The cost to analyze quality/scrap production data was minimal when using an integrated Quality Management System (aka Conformance Portal).
The first quality study on scrap paid for the Conformance Portal many times over.