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Challenges:

• High product scrap rate
• Made on hard automation line, many years of development, resistance to change
• Intermittent complaints in the field about motor noise

Achievements:

• Reduced scrap rate by 95%
• Total Annual Savings: $500,000
• Used QRC® to investigate processes for root causes
• Found correlations
• Field complaints effectively eliminated

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Challenges:

• Unit cost $300 over current target
• Added weight due to corporate mechanisms “carried over”
• More complexity due to new occupant sensing equipment
• Export requirements for rear seat impact of loose items

Achievements:

• Total Annual Savings: $4,148,000
• Reduced complexity of the product design and improved quality
• Reduced part count 13%
• Reduced number of operations 9%
• Reduced labor cost $4.12 per set
• Reduced material cost $16.62 per set
• Reduced total product cost $20.74
• Reduced weight 19.4 lb. per set

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Challenges:

• Execute a “no prototype” design – direct to production tooling schedule
• Poor quality history with previous supplier designs

Achievements:

• Reduced complexity of design allowed streamlined tooling
• Total Annual Savings: $5,170,000
• Reduced part count 27%
• Reduce number of operations 17%
• Reduced labor cost $4.70
• Reduced material cost $7.60
• Improved quality cost burden on each unit
• Reduced Cost of Quality $13.08
• Reduced total product cost $25.85
• Weight savings of 4.2 lb.

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Challenges:

• Substantial weight reduction – theoretical target of 20 lbs/unit
• Assembly complexity was also an issue

Achievements:

• Reduced weight by 13.8 lb.
• Tooling cost reduced by $750,000
• Weight reduction was gained through composite structure integration
• Reduced complexity of the product design
• Reduced part count 18%
• Reduced number of operations 53%
• Reduced labor cost 59%
• Tooling lead time reduced by 9 weeks

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