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Tuesday, October 17, 2017
Case Studies

Six Sigma

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Case Studies

Nothing makes an argument of the power of a process like success.  Take a moment to read some of the case studies below to see how The ROI Alliance can help your business.

Total Savings: $23 million / year

Description of Problem

A major steel company was adding new equipment to an existing sheet coating line to improve the line speed. The line coats steel sheet for the automotive and distribution industries. The equipment had already been purchased, but since the technology had not been used before in the US, only the most basic process settings were known. The client knew that experimentation would be needed to optimize these settings, but the coating line was overbooked hence no activities were being performed prior to the scheduled installation.

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Initial Year Sales of New Product: $2.8 million

Description of Problem

This project took place at a company that develops and manufactures complex polymer mixtures which are then manufactured as parts. A new product needed to be developed to improve a current product in terms of product performance and to reduce a seasonal high scrap rate. The company is a leader in their market, but during summer months the polymer parts they manufactured experienced high scrap and rework rates, requiring personnel to work overtime to make enough parts to fulfill orders. While projects were ongoing to identify and fix this problem in existing products, new products were being demanded by their customers. This particular product, if successful, showed great promise in expanding a current market sector. The company decided to use our Design for Six Sigma (DFSS) methodology.

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Total Savings: $70 million / year

Description of Problem

A steel rolling mill was considering changing suppliers for rolling mill lubricant. Mill lubricants are critical to a variety of product characteristics, but to assess multiple vendors required fully replacing the lubricant on the mill and running trial production through the mill and the remaining processing steps so the sample size was limited. There were two different types of annealing furnaces in use, and the lubricant might very well have responded differently to the two types. For each furnace type, there were two furnace practices tested. Additionally, one of the vendors changed their formulation in the middle of the study to try to improve their ratings.

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Total Savings: $341,149,000 as identified by the client.

Over the course of a six-year engagement at a manufacturing Fortune 500 company, ROI member consultants worked on a number of projects.  At the end of the engagement, the company calculated bottom-line contributions of these projects.  A matrix was generated to show these projects, the cost savings, and the technique used to capture the savings.

This matrix has been re-coded to hide the actual project and department names to protect our client. Projects are listed across the top by department while the left side lists the targeted areas for improvement. The intersection of the rows and columns shows which targeted areas were impacted by each project. The methodologies used to complete the projects are shown on the bottom.

View the Graph

News Alerts
bpe_book_sm Steven M. Ouellette's new book, Business Performance Excellence, is now available!

 

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