A manufacturer partnered with DISHER to reduce the scrap rate of an assembly from 7.7% to under 2% in six months.
DISHER met with the customer’s team at their facility to observe the failure modes and define the problem. Four possible contributors for the high scrap rate were identified. DISHER applied a Design of Experiment (DoE) to assess the relevance of each of the four factors in question. The current state was tested and measured.
DISHER and the customer analyzed the results from the plant trials and concluded that the screw type was the root cause. It was the most significant factor in causing the defects to occur. Backed by data, the team confirmed a recommendation to implement a design change which replaced the current screws with dog-point screws. The change was approved and implemented by the customer. The team verified the improvement through measurement.