$1Billion Manufacturer of Aluminum

• Initial run at rate: 200/day
• Initial FTQ: 60%
• Initial scrap rate: 30%
• Capable process: No

• Eliminated 6 special machines and replaced with 5 Axis automatic machining centers
• Revised principal locating scheme of the assembly process
• Re-designed automatic boring units and clamping sequence
• Revised the TIG welding process through robotic software advancements and component fit quality
• Revised control parameters of the aluminum extrusion process
• Mentored functional departments to train managers and implement processes, systems and data control

• Current run at rate: 1,200/day
• Current FTQ: 95+%
• Current scrap: 2%-5%
• Capable process: Yes