Problem: A manufacturer did not understand what contributed to the quantity of product shipped each day. They did a lot of work to keep production moving and reduce downtime, but it never seemed to impact their ability to ship more units
Causes
- 165 variables were tracked daily including:
- Downtime
- Defects per unit
- Model mix production (48)
- Model mix labor (48)
- Actual labor per department (15)
- Quality per department (8)
- End of line defects
- First Time Quality
- Material shortages
- Off line inventory
- Repair hours per unit
Solutions
- Identified top 7 contributors to product shipped
- Departmental quality (2 departments)
- Repair hours per unit
- First time quality
- Labor in repair dept.
- Off line inventory
- One model
- Analyzed First time quality (units not shipped within 4 hours)
- Identified the largest quality issues that prevented units from being shipped
- The largest reason for not shipping in 4 hours were trucks with nothing wrong
- Additional defects were identified that were more traditional such as brakes
Result
- The company felt that had staff to address the issues. They merely needed help wading through all the data to determine root causes.
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