| Copeland Corporation, manufacturer of compressors, incurred large amounts of scrap and rework from one production line. The company developed a team to investigate several items, such as individuals following procedures, producing parts to specifications, auditing procedures, and proper documentation. The team targeted and achieved the 25% goal in reduction of scrap and rework. The project lasted four months and included; implementation of interventions, analysis of scrap and reject reports, applying test statistics to validate improvements, and recommendations for further analysis.; The team developed and implemented several objectives, including an internal benchmarking exercise to evaluate the process for improvements. The team implemented process improvements to target methods of communication, involvement, and commitment. The team also implemented an internal audit program to monitor the process and provide evidence that individuals are following documentation developed by the process improvement. Further, the team revised the material review system for increased control of defective material. |
