Projects
Extracts from Six Sigma Projects
✔ Scrap reduction in the production of antishock dampers
✔ Process optimisation for the finishing of galvanic parts of the chassis
✔ Reduction of multiple EOL tests for front axis parts
✔ Reduction of the „non value adding“ work with n.o.k.- parts of a driving chain
✔ Reduction of wire breaks and optimisation of the winding parameters
✔ Rework reduction for rotation dampers
✔ Scrap reduction at a hydraulic assembly of chassis parts
✔ Task Force project for dampers in cooperation with 5 suppliers
✔ Reduction of scrap costs in the mechanical chipping of truck operating parts
✔ Analysis of the „Cost-Price-relationship“ of sinter parts
✔ Optimisation of „delivery on time“
✔ Optimisation of the adjustment steps at a Front production
✔ Productivity increase (Automotive Business)
✔ Increase of the amount of „Good pieces“ and optimisation of the primary check of the mass production of hydraulic chassis parts
✔ Optimisation of „SOP“ of the mass production of hydraulic chassis parts
✔ Process optimisation of plastic laserwelding
✔ Optimisation of the plastic injection process for automotive internal door furnishings
✔ Optimisation of the plastic injection process for the automotive internal dashboard fittings
✔ Reduction of defects within the injection process (contact systems)
✔ Reduction of time offset within the injection process (contact systems)
✔ Reduction of stock of a large scale production for hydraulic gear compontents
✔ Reduction of damage of shockabsorbers within automotive transportation
✔ Reduction of stock (systematic analysis of the root causes for excess stock and low stock turnover within multiple projects)
✔ Optimisation of the provision of trains
✔ Reduction of scrap and inventory cost
✔ Error rate reduction in the drill production
✔ Reduce scrap costs of hydraulic sub-assemblies
✔ Leaking AL- component after the laser welding
✔ Waste reduction and productivity improvement in a hydraulic assembly
✔ Reduction of defect costs for the laser welding process
✔ Increasing the application rate of a pipe cutting machine
✔ Increasing productivity in the production of digital cameras *
✔ Increased productivity of a welding centre
✔ Waste reduction module assembly
✔ Optimizing the cycle time of a calendar
✔ Complexity reduction of generator rotors
✔ Optimizing planning processes in plant
✔ Throughout optimization in chemical plants
✔ Optimization of a plastic injection moulding machine for automotive interior fittings
✔ Increase on-time delivery and availability of materials for equipment installation
✔ Cost reduction in doors of smokers
✔ Optimization of the return process of electronic spare parts
✔ Reduction of rework in the commissioning of new plants
✔ Optimization of the cycle time for laser welding systems
✔ Mislabelled components
✔ Density of channels with gas filling
✔ Reduction failure rates of high-frequency generators
✔ Life cycle in high-frequency generators: Preventive Service
✔ Reducing warranty costs for laser cutting machines
✔ Improvement of the security of supply of raw materials
✔ Reduction of delivery risks from a small number of suppliers of raw material
✔ Shortening lead times (focus: material income, QA and production approvals for recipes)
✔ Reduction of the number of change orders and credits
✔ Increased productivity by reducing the interference
✔ Reducing downtimes to plant xy
✔ Waste reduction
✔ Reducing lead time of bulk products
✔ Increased performance of washing equipment
✔ Reduce disposal costs and yield losses
✔ Reducing lead time of reporting and releases
✔ Reduction of rework to ensure the quality of mixtures
✔ Optimizing the use of cork grinding flour for the production of floor coverings ✔ Optimization of scrap of mixing ✔ Optimization of disposal processes ✔ Optimize energy management and water heating ✔ Paper, cardboard and paper processing ✔ Reduction of intermittent downtimes on board shaping machine ✔ Reduction of scrap compound coating ✔ Reducing PE edge trimming ✔ Reduction of scrap at roller ✔ Enhance productivity at COEX systems ✔ Reducing solvent consumption ✔ Reduction of rejects ✔ Reducing inventories of raw materials / RF and finished goods
✔ Optimization of the development process for a manufacturer of high quality watches
✔ Optimization the usage of space in a development centre
✔ Shorten the processing time of VV ‘s in the employee improvement programme
✔ Optimization of space usage
✔ Optimization dispatch process
✔ Optimization package delivery service process
✔ Relocation of production to a new plant
✔ Engineering and relocation of an entire branch of production
✔ Rough cost estimate process optimization factory planning
✔ Optimization of the application process
✔ Lean Action Workout (LAW) for immediate implementation of the improvements in the main processes
✔ Reduction of call volumes
✔ Change Management (IT Changes)
✔ Appropriate service level agreements in the field of technical services
✔ Reduction of service costs (logistics IT spare parts)
✔ Appropriate Service Level Agreements (SLA’s) in the field of technical services
✔ Increased sales efficiency (sales of IT services)
✔ Shortening lead times and reduce costs in repair processes
✔ Optimization of the service process in an amusement park
✔ Optimization of a call centre staffing at an amusement park (depending on incoming customer calls)
✔ Increasing the booking probability for new customers at an amusement park
✔ Optimization of maintenance at an amusement park
✔ Optimization of the goods sold at an amusement park
✔ Increase customer satisfaction at the buffet at an amusement park
✔ Improvement of the House -keeping process in an amusement park
✔ Optimization of the property planning at an amusement park
✔ Optimization of the repair process in Supply Operations
✔ Package audit process optimization package service process
✔ Evaluation of the reliability of the repair data entry
✔ Optimization complaint process in Operations
✔ Inventory Optimization (systematic analysis of the causes of excessive inventories and low turnover (on a number of projects)
✔ Optimization of air freight costs
Design for Six Sigma – Projekte
✔ Entwicklung einer elektrischen Fahrwerkskomponente
✔ Entwicklung einer neuen Anwendung zur Fahrwerksdämpfung
✔ Entwicklung eines Standardfedertellers
✔ Entwicklung einer Dichtungsführungseinheit
✔ Entwicklung eines neuen Lackes
✔ Kältemittelverdichter
✔ Luftmanagement
✔ Luft-Wasser-Management
✔ Anlage zur Herstellung von Isolierplatten
✔ Fugen – Designs bei PKWs (2 Projekte)
✔ Brennstoffzellen im Fahrzeugbau
✔ Weichheit von Interieur-Schaumteilen
✔ Batterien für umweltfreundliche Fahrzeuge
✔ Elektrische Lenkung (Geräuschthemen)
✔ Moduldach in Fahrzeugen
✔ Amplituden sensitive Dämpfer (ASD)
✔ Dichtheit von Heckmodulen
✔ Geräuschthemen bei Außenspiegeln
✔ Gepäckraum-Rollo
✔ Fahrwerksbaugruppen (Lebensdauer, Vorspannkräfte)
✔ Systematische Erarbeitung von verschiedenen Designkonzepten (Axiomatic Design)
✔ Präventive Bewertung der Konzepte hinsichtlich Funktionalität, Komplexität, Risiken und Kosten
✔ Detailliertes Prozess-Design für das gewählte Konzept
✔ Entwicklung der relevanten (hypothetischen) Prozesstransferfunktionen
✔ Planung und Durchführung der erforderlichen Versuche
✔ Datenanalysen zum Nachweis der Transferfunktionen
✔ Konzentration auf einen Coatingprozess
✔ Ableitung, Definition und Einführung geeigneter Messgrößen
✔ Bestimmung verifizierter Ursachen
✔ Ermittlung der optimalen Settings
✔ Minimierung von Risiken
✔ Festlegung benötigter Prüfungen, SPC-Punkten, Stichprobengröße
✔ Systematische Quantifizierung der Risiken in einer vollautomatischen Verpackungslinie
✔ Ableitung, Definition und Einführung geeigneter Messgrößen
✔ Bestimmung der verifizierten Ursachen
✔ Ermittlung vorherrschender Defektmechanismen
✔ Präventive Sicherstellung eines Lean-Designs
✔ Entwicklung und Einführung einer Kommunikationstafel für die Produktion
Gemini said
✔ Anwendung von Tools in der Forschung und Entwicklung chemischer Produkte und Prozesse
✔ Axiomatic Design (Entwicklung funktionaler und physikalischer Strukturen, Berechnung des Informationsgehaltes von Designs, Kopplungsanalysen)
✔ Systematisches Generieren von Konzepten
✔ Funktionsanalysen
✔ Systematischer Umgang mit „weißen Flecken“ in der Forschung
✔ Systematische Beurteilung und Auswahl von chemischen Designkonzepten
✔ Integration von Data Mining und Text Mining
✔ Anwendung von Tools in der Entwicklung chemischer Prozesse
✔ Fortführung der kausalen Kette vom Produkt- zum Prozess-Design mittels „Axiomatic Design“
✔ Versuchsplanung DoE und Simulationen
✔ Toleranzen in der Chemie
✔ Entwicklung eines geeigneten Stichprobenverfahrens für attributive Produktmerkmale in der Lebensmittelindustrie
✔ Aufbau der kausalen Kette von den Kundenanforderungen zu den Produkt- und Prozessmerkmalen
✔ Entwicklung eines allgemein gültigen Berechnungsverfahrens für Stichprobengröße – und Frequenz
✔ Verknüpfung von Stichprobengrößen, attributiven Fähigkeitskennzahlen, der Zuverlässigkeit von Mess- und Prüfsystemen und den Risikobetrachtungen in FMEA‘s
✔ Fokussierung präventiver Prüfungen
✔ Realisierung einer Schnittstelle zum Informations- und Kommunikationssystem
✔ Entwicklung eines maßgeschneiderten IT-Supports
Projekte „Management Control & Reporting – System“
✔ Systematische Analyse und Optimierung des Management Control & Reporting-Systems (MCRS)
✔ Informationsfluss und Kommunikation
✔ Regelschleifen hinsichtlich Termin, Kosten und Qualität
✔ Dokumente
✔ Eignung vorhandener Kennzahlen, fehlende Kennzahlen
✔ Isolierte Aktivitäten
✔ „Top-down“-Planung und „Bottom up“-Reporting
✔ Erfassung des Ist-Systems für einen Bereich mit ca. 1200 Mitarbeitern
✔ Analyse des Zusammenspiels von Vertrieb, Entwicklung, Disposition, Einkauf, Produktion mit mehreren Meisterbereichen, QM, Logistik
✔ Erarbeitung eines „Brown Paper“ zur Darstellung und Analyse des Ist-Systems mit allen tatsächlichen Dokumenten und IT-Systemen
✔ Analyse von Medienbrüchen
✔ Sukzessive Entwicklung eines geeigneten und präventiven Sollsystems mit passenden Kennzahlen
✔ Systementwicklung mit Fokus auf eine Kausalität zwischen den Kennzahlen
✔ Erfassung des Ist-Systems für einen komplexen Entwicklungsbereich
✔ Analyse des Zusammenspiels von Vertrieb, verschiedenen Entwicklungsabteilungen, Labor, Disposition, Einkauf, Zulieferern, QM, Logistik
✔ Erarbeitung eines „Brown Paper“ zur Darstellung und Analyse des Ist-Systems mit allen tatsächlichen Dokumenten und IT-Systemen
✔ Analyse des Ist-Systems
✔ Ableitung von kurz- / mittel- und langfristigen Maßnahmen zur Verbesserung des Systems
✔ Systementwicklung mit Fokus auf eine Kausalität zwischen den Kennzahlen und Begleitung bei der Einführung
