Introduction:
In the intricate world of die casting, achieving a high yield is not just a goal; it’s a necessity. This case study unfolds how Proval Consulting tackled a critical challenge for an Automotive OEM dealing with shockingly low Die Casting Yield, leading to operational disruptions, excessive scrap, and soaring costs. Through a data-driven and strategic approach, Proval not only transformed the yield but also delivered substantial cost savings.
Client Background:
Our client, a major Automotive OEM, faced a pressing issue with Die Casting Yield, which plummeted below 10%. This not only triggered production line downtimes but also resulted in high scrap rates and escalated air freight costs to meet demand.
Objectives:
- Significantly improve Die Casting Yield.
- Eliminate operational disruptions caused by low yield.
- Reduce scrap rates.
- Mitigate air freight costs.
Problems Identified:
Proval Consulting conducted an in-depth analysis to uncover the root causes behind the abysmally low Die Casting Yield. The strategic approach included the implementation of various statistical methodologies and Lean principles:
Solutions Proposed:
Pareto Charts:
- Identified and prioritized the most significant factors contributing to low yield.
- Focused efforts on addressing the critical few issues with the most substantial impact.
Cause & Effect Analysis:
- Investigated the relationships between various factors influencing the yield.
- Pinpointed specific areas for improvement in the die casting process.
Design of Experiments (DOE):
- Conducted controlled experiments to understand the impact of different variables on yield.
- Analyzed the results to optimize the die casting process.
ANOVA (Analysis of Variance):
- Utilized statistical analysis to assess the significance of variations in process parameters.
- Identified and addressed factors contributing to inconsistencies in yield.
Control Charts:
- Implemented control charts to monitor and maintain the stability of the die casting process.
- Proactively identified and rectified deviations from the desired yield.
Process Capability Analysis:
- Assessed the capability of the die casting process to meet specifications.
- Implemented measures to enhance process capability and consistency.
Value Stream Mapping (VSM):
- Mapped the entire value stream to identify and eliminate inefficiencies in workflow.
- Streamlined the die casting process for improved overall efficiency.
Implementation:
Proval worked closely with the client’s team to implement the recommended changes. Training programs were conducted to ensure the seamless adoption of new processes, and continuous monitoring allowed for real-time adjustments.
Results:
The impact of Proval’s interventions was nothing short of revolutionary:
Yield Improvement:
- Die Casting Yield increased from a meager 10% to an impressive 92% within just two weeks.
- Operational disruptions caused by low yield were eliminated.
Cost Avoidance:
- The client experienced significant cost avoidance, totaling around $350,000.
- Reduced scrap rates and air freight costs contributed to substantial savings.
Conclusion:
Proval Consulting’s data-driven and strategic approach, utilizing Pareto Charts, Cause & Effect analysis, Design of Experiments, ANOVA, Control Charts, Process Capability, and Value Stream Mapping, not only turned around the Die Casting Yield but also delivered substantial cost savings for the Automotive OEM. This case study exemplifies Proval’s ability to identify and address complex manufacturing challenges with speed and precision.
Ready to optimize your manufacturing processes and achieve remarkable results? Connect with Proval Consulting for tailored solutions that drive efficiency, enhance quality, and generate significant cost savings for your business
Project Details
- Category: Operational Consulting
- Client: Automotive OEM dealer
- Location: U.S.A
- Duration: 3 months
- Results: 1.Die Casting Yield increased from a meager 10% to an impressive 92% within just two weeks. 2.The client experienced significant cost avoidance, totaling around $350,000.