Case Study: Revitalizing Efficiency and Quality in Rework Processes

Challenge:

In a challenging scenario where over 5,117 manufactured outdoor retail consumer products faced complex issues rendering them unsellable, our client found themselves with a significant problem. These consumer products required intricate multi-step rework, and with shipping targets to meet, an empty warehouse, and no existing rework process in place, the situation demanded an innovative and rapid solution.

Solution:

Recognizing the urgency and scale of the task at hand, our team took a proactive approach. We created and implemented a production line rework process from the ground up, leveraging the expertise of each team member. The strategy involved breaking down the rework process into individual steps, allowing each team member to focus on one specific task repetitively.

Key Steps:

Structured Rework Process: Established a systematic rework process, ensuring that each team member performed a specialized task in a continuous cycle.

Removal of waste: ?By removing wasted rework steps via the use of an endoscope to verify software versions, introducing additional tools to eliminate tool bit changes, and removal of wasted movements by having a cart for every reworker so all tools travel with the reworker we were able to maximize the efficiency of the rework performed.

Mistake Proofing: By implementing mistake-proofing solutions such as limiting the torque speed to prevent stripped screws, keeping screws that are loosened within the housing, 4 eye checks for each rework step performed, and required fields placed within the data capture system, we were able to 100% ensure high-quality output.

Layered Quality Checks: Integrated comprehensive quality checks at multiple stages of the production and rework process, guaranteeing the highest standards were maintained.

Cloud-Based Traceability: Implemented a cloud-based traceability system, providing customers full transparency into the rework journey, from inception to completion.

Achievements:

Efficiency and Defect-Free Rework: Through meticulous planning and execution, we achieved 100% defect-free reworked units. The structured production line and layered quality checks played a pivotal role in ensuring precision and accuracy.

Exceeding Shipping Targets: Despite the initial challenge of an empty warehouse and the need to meet customer shipping targets, our rework process surpassed expectations, ensuring not only timely deliveries but also exceeding the targets set.

Daily Output and Team Efficiency: With an average of 40 team members, we achieved a remarkable average daily output of 160 reworked units. Assigning specific tasks to each team member proved instrumental in optimizing efficiency.

Customer Satisfaction: Implementing cloud-based traceability gave customers real-time visibility into the rework progress. The result was a satisfied customer base that appreciated transparency and the commitment to delivering high-quality products.

Conclusion:

In overcoming the challenge of reworking over 5,117 manufactured outdoor retail consumer products without an existing process, our team's innovation and dedication led to a success story. By creating a structured rework process, implementing layered quality checks, ensuring full traceability, eliminating unnecessary rework steps, removing wasted movements, and ensuring each rework step was mistake-proof, we not only met but exceeded customer expectations. This case exemplifies how strategic planning and a commitment to quality can turn a seemingly insurmountable challenge into a triumph.