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Case Studies

national-oilwell-varco.avif
National Oilwell Varco

ISSUE: Production process took six weeks and costs were high.

SOLUTION: Mapped the process, identified inefficiencies and led a complete improvement programme.

TOOLS USED:

  • Process mapping

  • Lean + Six Sigma (DMAIC)

  • Jig + tool design
     

RESULTS: Cycle time reduced from 6 weeks to 1 week and First-time pass rate increased from 66% to 98%

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Renishaw

ISSUE: Major new product development problem; yield of 25% onSprint touch trigger probes.

SOLUTION: Ran 8D project to get to root cause and implement solutions.
 

TOOLS USED:

  • DfX (Design for Excellence)

  • Six Sigma (DMAIC)

  • Gated milestone adherence
     

RESULTS: Alpha build yields increased to 95%

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Kohler Mira Showers

ISSUE:  Low FTPR, yield and equipment efficiency.

SOLUTION: Led a structured improvement programme using

Industry 4.0 and digital manufacturing solutions.
 

TOOLS USED:

  • 8D, Gemba Walks

  • ANDON

  • Value Stream Mapping
     

RESULTS: 1FTPR improved from 60% to 95%, yield from 45% to 92% and OEE from 52% to 68%.

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