Other Industry Results
The combination of Hagen’s OEE software, Six Sigma tools, and lean manufacturing system consulting have generated dramatic breakthroughs in manufacturing process improvement for our customers. See the following profiles that highlight these accomplishments:
| Situation |
Results |
Cylinder block line; impossible to improve throughput without capital investment.
Supposed to have 38 operators. Actual was 50 operators with $2,000,000 overtime issue.
Line runs slow because of drill bits breaking and cannot fix.
Disc brake rotor quality problem with concentricity off by several thousands – rate of failure – 50%
Team of six working seven months found 60 possible causes and no solution |
Avoided spending capital to increase output
In 4 weeks solved drill bit bottleneck and 3 other bottlenecks
Four projects in four weeks
Found root cause in 1.5 days
Solved problem
Increased throughput 30%
Saved over $1,000,000 in overtime
Capital Required $0 |
Aluminum Smelter - Carbon Plant
Capital necessary for Improvement |
Project length 3 months
Increased plant efficiency by 28%
Capital Required $0 |
Aluminum Smelting Operation
Must reduce contracting costs this year by 25% |
Project length 4 months
Annualized Profit Benefit $10,000,000
Capital Required $0 |
Plastic injection molding
40 Production units
Data pointed to scrap and downtime for improvement efforts - factory still losing money |
Focused on slow-running which put factory profit "in black"
Project length 6 months
Increased speed and output 42%
Capital $0 |
Sister Plant-Plastic injection molding
"fogging" on clear parts
Several improvement initiatives failed to solve "fogging" problem |
"fogging" problem solved in 6 weeks
Improved output 15%
Annualized Profit Benefit $1,500,000
Capital Required $0 |
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