Reducing Scrap in a Machining Process

Reducing Scrap in a Machining Process

Client:
A “greenfield” startup facility creating 1-3 micron tolerance machined parts was experiencing high rates of scrap product during the ramp-up to full production. The excessive scrap was creating cost issues and was jeopardizing customer production schedules.

Goal:
Reduce the amount of scrap being produced by 80% through the use of the Six Sigma DMAIC methodology. The estimated value of the project savings at full production was in excess of $1 million per year.

Results:
Utilizing the DMAIC methodology, and working with an eMRI consultant, the Black Belt and the team were able to identify sources of both common cause and special cause variation. Key tools utilized during the project were measurement system assessment and design of experiments. Scrap was reduced by 87%.

Savings:
$1,300,000 per year.