Success Stories
Consumer
| Beer Bottle Breakage | This Design for Six Sigma Project focused on eliminating the breakage of beer bottles during the filling process at the brewery. The design changes focused on the glass composition, the bottle mold design, and the glass making process controls. |
| TQM in the Furniture Industry | This success story was first presented at the ASQ Annual Quality Congress in 1992. The project started in late 1989 and our involvement spanned two years. You will notice a close similarity to Six Sigma DMAIC and DMADV Improvement Processes in this presentation. It's an example of how TQM was successfully implemented prior to the Six Sigma movement. The complete Success Story lasts 14:32 minutes, but well worth it. |
Defense
| Defense System Cost Reduction | The Navy has traditionally worked with suppliers to drive procurement costs down. In this collaborative effort the AEGIS Gun and Guided Missile System was identified as a target for re-design and cost reduction. This project example focuses on one component in the system, namely the elevation shaft. In the original design this shaft was comprised of 15 components with multiple outsourced operations. Many other components and systems were addressed as well, but lets look at the shaft. See what happens after the DFSS project. |
Health Care
| Medicaid Hospital Process | Coming Soon |
Industrial
| Diplex Filter PCB | In the cable and telephony industry the diplex filter is the conduit for two way communications across the single pipe of the cable. This rf device creates a demilitarized zone between the low frequency send signals and the high frequency user receive signals. This allows the user to have high speed internet, order movies, and ask for other cable system provided content. Tuning of the diplex filter required by hand manipulation of wire wound torroids to achieve the proper waveforms. The original waveform specification was unclear which made tuning difficult and prevented the filters from pluging and playing in the amplifiers which reside about every 1 to 2 miles of cable. See how this Lean Six Sigma project tackled this issue. |
| Elevator System | This Design for Six Sigma project focused on hydraulic elevator systems. The system is highly complex, but after the functional cost modeling process was completed the cabs and the hydraulic jacks were the best targets for re-design. See the results of the DFSS process on the Hydraulic Elevator System. |
Service
| Customer Service Claims Process | This project focused on the customer service claims process for a wood flooring manufacturer. The customer servce organization had been centralized and moved out of the plants creating some disconnect between engineering, production, quality, customer service, distributors, and ultimately the consumer. |
| Purchasing Process for a Cruise Line | This project focuses on the purchasing, procurement, and logistics process for shipboard replenishment of food, beverage, and hotel supplies. Ships are floating hotels and also warehouses. See the results of a Lean Six Sigma project that applied purchasing best practices in this service industry. |
