EBS Group Home Page
About EBS Group
EBS Group Services
Strategic Wing
Quality Management System
Human Resource Wing
Supply Change Management Wing
Contact Us
Client Association
Benefits  of Partnering
Our Team of Experts
Career Opportunities
Case Studies
Photo Gallery
Business Enquiry Form
“Solving Chronic Manufacturing Problem”


Client had very high rejection which leads to Loss of 40 million Indian rupees as cost of Poor Quality.

The manufacturing processes includes – Pressure Die casting and machining
Sector – Automotive

EBS Assessment Process:

Done a detailed operational assessment as per EBS unique methodology .

The initial assessment identified following area of improvement :-
  • The Manufacturing process is not validated with proper systematic approach
  • FMEA of the process not capturing all the variation and not linked to DFMEA ,MSA & SPC
  • The SOP of the process which is followed by operator is not defined properly
  • Manufacturing process audit is not done within the organisation
  • Company has not followed structure Six Sigma tools to resolve the existing chronic manufacturing problems
Project Approach & Deployment Solution from EBS:

EBS strongly believes in starting with Process Approach for resolving any business issues.
  • Establishment of Process in line with PFMEA approach covering incoming source of variation and closely monitoring the process dominance which leads to problems
  • Linking of all the TPM concepts with FMEA process characteristics
  • Detailed MSA study done related to the blow hole checking and established proper R&R as required for the process.
  • Done detailed analysis of variation using various advanced statistical tools and improvement points indentified.
Implement Change:
  • As per the detailed study the luger speed and die coat application time changed
  • The runner design of the die changed
  • The cooling system modified to ensure that the temperature is between 132 to 152 at various places
  • Melting of aluminium ingot only is melting furnace
  • The specification of the RM changed as per the study using Paired comparison ( tool)
  • The Manufacturing Audit introduced
  • PFMEA. SPC, MSA, TPM all effectively integrated and also same is integrated with Supplier Processes.
Sustain Change:
  • Weekly review by Production head introduced to ensure deployment of revised processes , SOP and capturing of  Data related to Blow hole rejection
  • Operator has been trained to follow SOP points and Trained to capture  causes whenever rejection observed after the machining process , The data captured on daily basis along with Quality person
Project Results:
  • 10 % productivity improvement
  • COPQ due to blow hole rejection came down to 2 million per year
  • 20% reduction in Machine Breakdown 

© 2004-2012 The EBS Group

Site Map