We’ve discovered a hidden chance, presenting us with a new opportunity to save resources.
Everything seemed fine, but tiny cavity variations revealed new opportunities.
3 grams per bottle, imagine the savings!
A process can meet specs, but what if we push beyond them?
Loose tolerances could be costing us.
For Mr. Muscle bottles, a 4-cavity mold showed significant variation—bottles from cavity 4 were smaller, resulting in less liquid volume. And this difference was statistically significant.
By tweaking the process, we could meet expectations and save money.
Small process tweaks saved tons for SCJohnson.
Our goal was simple: Arrest the dominant category of variation to optimize process efficiency and product quality.
Variation that occurs over time during production, such as shifts, trends, or cycles in the process. This is also referred to as time-to-time variation.
Variation within a single unit or component, often due to differences across specific locations (e.g., different cavities in a mold or varying points on a surface). This is also known as within-piece variation.
Repeated variation following a cycle, such as changes due to machine cycles, production batches, or shifts. It is often associated with equipment performance or operational factors that periodically change.
We saw a 5% reduction in material waste annually, equivalent to saving tons of liquid across our global production facilities. This solution has since been replicated across other production lines
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