A Hard Disk Cover manufacturer, in which the key process is Machining uses Real-time SPC Software to reduce their On-Hold Items from 14% to 2.5% in less than 6 months.
Case Study: Reduce On-Hold Items (OHI) from 14% to 2.5%
In the Real-time SPC Software implementation in this factory.
- A product (hard disk cover) is sampled every hour and sent to the QC Laboratory for testing.
- In the QC Lab, CMMs (Coordinate Measurement Machines) are used to measure the Product Sample.
- Immediate after all parameters for the Sample are measured by the CMM, the data is automatically transferred through LAN to the Real-time SPC Software Server.
- The Real-time SPC Software Server will analyze the data sent to it from the CMM to check for Out-Of-Specifications and Out-Of-Control Conditions.
- When the Real-time SPC Software Server detects any Out-Of-Specifications and Out-Of-Control Conditions, it will send an On-screen Alert to the Monitoring PCs that are located in the Production Area informing on the parameters which are Out-Of-Specifications or Out-Of-Control and the Machine that manufactures the Product Sample
- Whenever the Technicians and Engineers in the Production see An On-Screen Alert on the Monitoring PCs, they will investigate the problem at the machine.
Within 3 months of the implementation of the Real-time SPC Software, the factory achieves the following results:
- On-Hold Items reduce from 14% to 2.5%
- Rejects reduce from 5% to 0.3%
- Manpower (used for Reporting purposed) is reduced by 40%
- Response Time to Customer Queries reduces from 1 day to 30 mins
- Customer Report Preparation Time reduces from 2 weeks to 1 day