Available in PDF
Fundamental Problems
- Product flow impeded by batching and storage
- Non productive inventory
- Visual noise & lack of tool organization
- Multiple inspection steps
- Poor layout required excess walking
- Excessive TAT and headcount
|
Solutions
- Workcell layout for 80% of volume in automated core
- Operators cross trained to operate multiple instruments
- Standard work for each test
- Single piece first in/first out processing
- Pull inventory management
- Supplies at point of use in sequence of use
|
 |
 |
| Metric |
Base |
After |
Improvement |
| Testing accuracy |
3.4 Sigma |
5.2 Sigma |
86 DPMO |
| Cycle Time Average Test (min)* |
62 |
35 |
44% |
| Potassium * |
62 |
34 |
45% |
| Hemoglobin * |
53 |
22 |
58% |
| Protime * |
51 |
33 |
35% |
| Productivity Improvement |
|
|
14% |
| Production Capability** |
|
|
75% |
*Cycle Time measured from collection to verification
**Ability to increase testing volumes without adding FTEs
Base Operator Analysis
Before
After
