Challenge:
A leading auto component manufacturer faced 4.2% rejection rate causing significant rework costs and customer complaints.
Approach:
Deployed a full DMAIC project with MSA validation, process capability analysis using Minitab, hypothesis testing to identify 3 key root causes, and DOE to optimize process parameters.
Implementation:
Installed poka-yoke devices, redesigned die maintenance schedule using predictive indicators, implemented control charts for ongoing monitoring, and trained the quality team.
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