Situation:
Mid-sized manufacturer and supplier of small mechanisms and metal stampings constantly struggled with variation of stamped metal parts due to heat treating.

Solution:
ASG conducted comprehensive review of the supplier's Process Failure Modes and Effects Analysis (PFMEA) and Control Plans and provided recommendations to:

• Implement an error proofing strategy
• Assist the team with reviewing the Design FMEA to help identify key characteristics important to the function of the design
• Work with the heat treating supplier to minimize process variations

Result:
Supplier is no longer forced to inspect 100 percent of all outgoing material, allowing for a cost savings of approximately $15,000 monthly. Production efficiency has improved 15 to 20 percent. Supplier is now looking to implement additional Lean actions to further improve efficiency and reduce buffers / in-process inventory.