Molded in Graphic (MIG) Product Improvement
Project Description
This project utilized the DMAIC product improvement process with a distributed team that was located in Illinois, North Carolina, and South Carolina. The molded in graphic product had been under development for over a year but had a few problems holding it back from launching into production. The project team included the supplier who was developing the MIG graphic and the roto-molder who was the customer.
Problem Statement
The current molded in graphic is costly, requires large orders to be produced by the current supplier, requires a gluing operation, and the application process is labor intensive.
Goals and Objectives
Finalize the development of the new design MIG by solving the last few production problems which results in a graphic that is easily applied, self sticks, costs less, and can be produced in short production runs that align with the roto-molder’s demand requirements.
Follow the DMAIC Process which included:
- FMEA – Identify the Root Causes
- QFD – Assure all customer requirements are met and identify the factors for the DOEs
- Operational Definitions for evaluation of the roto-molded MIG
- A series of Designed Experiments to develop the solutions (2-3 week lead time for each DOE)
- Control plan and work instructions to maintain the gains
Summary of Results
Resolution of production problems was accomplished over a 5 month period using Webinar on Demand for team collaboration and completion of all project deliverables. This project created a win-win situation for both the supplier of the MIG who was gaining a new market and the Roto-Molder who was realizing cost savings and production efficiency. This project began in mid December 2009 and was completed in April 2010.
