Blower Motor Noise
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
Automotive Front and Rear Seats
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
Automotive Instrument Panel
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.
Composite Instrument Panel Weight Study
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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