Improving Pilot Plant to Production Success Rate

Improving Pilot Plant to Production Success Rate

Client:
When transitioning from product development (pilot plant) to full-scale production, a firm was experiencing a manufactured product failure rate of over 40%. The problem was getting progressively worse over time.

Goal:
Use the Lean Six Sigma methodology to reduce the failure rate to less than 25% within six months.

Results:
An eMRI led team was assembled and analyzed the transition between pilot plant and full production. It was determined that the measurement systems used at the pilot plant facility and in the production plants were different and there were significant differences in their performance (measurement error). Best practices measurement systems were identified and deployed across all facilities. The result was a decrease in failures from 40% to 20%.

Savings:
Not quantifiable.