Dr. Schneider is a tier-one supplier to the German car industry, excelling in first-class interior plastic components. Like many others in the industry, the company was facing increasing pressure to deliver cheaper products faster without compromising quality.
Delivery and outcomes:
Six Theta® identified as part of the solution
Pilot project showing 20% cost reduction and 30% faster running-in
Subsequent upskilling and certification of the entire engineering staff in Six Theta® robust design
Standardisation and integration of Six Theta® into the NPD/NPI model.
Pharmaceutical company – packaging line
Despite several and year-long problem-solving attemps the company was experiencing repetitive stops and unplanned downtime on an automated packaging line for a block-buster product. Apart from obvious production inefficiencies, more serious was the risk of lost revenue and inability to supply to patient needs.
Delivery and outcomes:
Structured problem solving and Six Theta® analysis revealed 14 hidden design weaknesses on the packaging line in one week
Six Theta® compliant solutions implemented over a few weeks reduced the downtime by 75% – remaining issues proved to be non-mechanical
Subsequently, a training program was designed to upskill production technicians with Six Theta® problem spotting skills for faster problem solving.
Nespresso
Following a very successful product introduction, the company was experiencing variation-driven quality issues in production and increasing customer claims leading to significant quality costs.
Delivery and outcomes
Six Theta® design review revealed several hidden mechanical design weaknesses
Decision to redesign the product and train the design team in Six Theta® robust design
Six Theta® robust design is now an integrated part of the company’s NPI process.
Micro Matic
Micro Matic – a mid-sized, high volume and world-leading beverage dispensing manufacturer – is aspiring world-class quality performance. With a key product showing unsatisfying first pass yield (FPY) performance, the company had been forced to install resource demanding QC activities to uphold its delivery performance. Internal problem solving attempts had not solved the issue.
Delivery and outcomes:
Six Theta® analysis identified a handful of hidden design weaknesses on both product and assembly equipment
Six Theta® compliant design solutions implemented and passed on to ongoing next-gen product development
