2009-10 Team Project Summaries

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3M
Knoxville, IA USA

Flexographic Value Stream Transformation

Presentation: Monday, May 24, 4:15 p.m. – 5:00 p.m.
Room: 261

Type of Team: Lean Six Sigma

The project was run to optimize one of 3M’s high-impact supply chains. It significantly reduced the supply chain complexity and length, resulting in improved yield and customer satisfaction and reduced defective parts per million. An array of quality tools were deployed including design of experiments, capability analysis, measurement systems analysis, Six Sigma methodologies, and lean methodologies, to mention a few.

 

St Paul, MN, USA

Abrasives Belt Fabrication Improvement Team

Presentation: Tuesday, May 25, 3:00 p.m. – 3:45 p.m.
Room: 261

Type of Team: Lean Six Sigma Continuous Improvement

Industrial abrasive "belt quality" has a new standard. For decades, "abrasive belt complaints" were the no. 1 industrial abrasives customer complaint. Combining Six Sigma DMAIC rigor and a "top 200" customer focus, this team has driven a step-change quality improvement every year for the last seven years. Abrasive belt fabrication is a complex "make-to-order" operation, with tens of thousands of end-users, hundreds of products, and belts sizes ranging from 1/8" in width to hundreds of inches in length. The top 200 list enabled the team to better define the critical VOC parameters, and categorize the critical issues. Through prioritization, robust test methods, experimentation, statistical data analysis, implementing improvements, and solid control plans, the journey was under way and continues today. The results speak for themselves; defects have been reduced by 97+ percent; from 12,000+ DPPM in 2002 to the low 300s DPPM in 2009. The business has saved hundreds of thousands of dollars per year.

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