Lean 6 sigma metrology - Productivity from enhanced metrology
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At INSPHERE we help companies wanting to improve productivity through the enhanced use of measurement data. We have developed our own methodology to provide a framework for sig metrology in a value added manner. This follows three stages. for each we have developed a toolset and techniques to ensure data is reliable, efficient and effective.
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Lean 6 sigma metrology - Productivity from enhanced metrology
- 1. INSPHERE Ltd Company Reg. 8769144 www.insphereltd.com Copyright of INSPHERE Ltd unless specifically stated otherwise Lean 6-Sigma Metrology for Aerospace
- 2. INSPHERE Ltd Company Reg. 8769144 www.insphereltd.com Copyright of INSPHERE Ltd unless specifically stated otherwise Aspirations for change • Improving quality processes to drive profitability – Reduce non-value added activity – reduce costs – Utilise data for value-added activity rather than just verification • Moving beyond a ‘gatekeeper’ approach to quality – Understand and control the process itself – Capture and correct non-conformance prior to adding further value – Utilise in-process data to correct and enhance the manufacturing process • Adopting data driven manufacturing as part of a right first time philosophy
- 3. INSPHERE Ltd Company Reg. 8769144 www.insphereltd.com Copyright of INSPHERE Ltd unless specifically stated otherwise An integrated Approach • Metrology needs to be considered and implemented as a holistic system. • Addressing individual elements in isolation will not yield significant business impact. • However improvements need to be incremental focusing on discrete areas. • As such an overall strategy is required to ensure all elements of the improvement programme are aligned.
- 4. INSPHERE Ltd Company Reg. 8769144 www.insphereltd.com Copyright of INSPHERE Ltd unless specifically stated otherwise Supply Chain Companies An integrated Approach In-House Manufacturing
- 5. INSPHERE Ltd Company Reg. 8769144 www.insphereltd.com Copyright of INSPHERE Ltd unless specifically stated otherwise Lean 6-Sigma Metrology - The INSPHERE framework for metrology improvement Effective Data Efficient Data Robust Data Utilise data for process improvement and right first time manufacturing processes Optimise metrology processes to maximise efficiency, miniming non-value added activity Ensure data generated is reliable and follows best practice processes and standards
- 6. INSPHERE Ltd Company Reg. 8769144 www.insphereltd.com Copyright of INSPHERE Ltd unless specifically stated otherwise Why? – De-risk current operations • Limit risk of escapes – Ensure compliance with standards • Quality (ISO9100 etc) + Customer specific (Rolls-Royce SABRe etc) What? – Calibration processes – Application of MSA to understand and monitor measurement capability – Equipment selection and alignment with specification – Operator training – Standardisation via SOPs, WIs for consistent operations – Application of metrology best practice principles Lean 6-Sigma Metrology Robust Data – Generating data you can trust
- 7. INSPHERE Ltd Company Reg. 8769144 www.insphereltd.com Copyright of INSPHERE Ltd unless specifically stated otherwise Lean 6-Sigma Metrology Why? – Reduce operational costs, increased profitability – Reduce TAKT times - Increase operational capacity – Future proof operations for growth What? – Metrology Process Analysis • Value stream maps, time value maps, value add charts • Five Laws of Lean, Seven Wastes – Design for manufacture analysis • Specification analysis - Tolerance, Datum structures – Measurement planning • What to measure, when to measure Efficient Data – Optimising the process to minimise non-value added activity
- 8. INSPHERE Ltd Company Reg. 8769144 www.insphereltd.com Copyright of INSPHERE Ltd unless specifically stated otherwise Lean 6-Sigma Metrology Why? – Enhancement of manufacturing processes through use of data • Increased accuracy and precision • Time, cost, quality improvements. – Known and controlled manufacturing capability • Design rules updated, less material use, more cost effective – Right first time manufacturing What? – Application of 6-Sigma methodology • Define, Measure, Analyse, Improve, Control • Monitoring and feedback, SPC, CPk – Data driven manufacturing solutions • Metrology guided automation, live feedback, adaptive assembly Effective Data – Manufacturing process improvement through value added metrology
- 9. INSPHERE Ltd Company Reg. 8769144 www.insphereltd.com Copyright of INSPHERE Ltd unless specifically stated otherwise Quality Cascade The principles of lean 6-sigma metrology can also be applied to supply chain companies. • This will help ensure products supplied are right first time, to the product specification. • Ultimately increasing efficiencies in the supply chain will lower bought-in product costs. Some considerations.. • Internal processes need to be in order first to provide suppliers with the correct specification for verification. • Carrot or Stick approach to adoption by suppliers • Supplier investment implications Supply Chain Management
- 10. INSPHERE Ltd Company Reg. 8769144 www.insphereltd.com Copyright of INSPHERE Ltd unless specifically stated otherwise info@insphereltd.com www.insphereltd.com Metrology Automation High-Value Manufacturing Research