9.1.1 Phase 0: Problem Statement

The automation system of a manufacturing company X during the fall quarter had over 45% downtime, resulting in an additional labor cost of $140,000 $145,000. If this trend continues within a year, the labor cost will exceed $500,000. A team of engineers and production staff were assigned to study the case. The objective is to reduce total downtime by at least half to a maximum of 22.5% and not to exceed that thereafter. This would allow customer demand to be met without the requirement of overtime and about 100,000 parts per week, which makes about 40% of X product.

Approach

First, the Lean Six Sigma team began with a process map SIPOC and flowchart, as shown in Figures 9.1 and 9.2, to clearly understand the process itself.

Figure 9.1: Process mapping.

Figure 9.2: Process flowchart.

9.1.2 Phase 1: Data Collection and Measurement

All process outputs relevant to downtime are attributing in nature and recorded in a networked database. Some of the issues that cause machine downtime are as follows:

• Fault description and frequency

  Machine data detailing all faults.

• Lack of parts

  Downtime accrued when the automation system does not run due to the lack of availability of a particular part in the assembly.

• Jam parts

  Downtime accrued when the automation system stops for a machine station fault until the time the machine is restarted.

• Reactive maintenance (RM)

  Downtime accrued during the time...