Broken Bases Scrap reduction in FD line

Abstract

A key reference point to verify the efficiency of a production line is its scrap performance. The FD breaker production line of company “ABC” is currently facing challenges due to broken nubs and corners defects of 3-pole bases impacting the scrap metric with an estimated 4.9K dollars per month. By using the Six Sigma DMAIC methodology, it was determined in which workstations was occurring the highest frequency of breakages. A 28% breakage rate reduction was obtained by improving fixture conditions, defining proper positioning methods and stricter WIP levels that improved the material flow. Key Terms ⎯ Pareto, Problem-Solving, Scrap, Six Sigma.