Defect Elimination – Case StudyCable Manufacturer - NSW, Australia

Defect Elimination

The Challenge

An electrical cable manufacturer in Western Sydney was experiencing a significant rise in extrusion related defects. Rates were more than 17% above the manageable baseline target. Previous attempts had been made to address the cause but had lacked implementation and sustainability strategies.

The Solution

EnterpriseIS investigated the previous projects conducted to address the defect rate and then consolidated the information. Data and information gaps were then filled through the course of a tailored applied learning model utilising Competitive Systems and Practices skill sets as a vehicle for engagement, implementation and sustainability.

The root cause of defects was found to be a combination of elements that required standardisation and measurement system analysis to regain process control and deliver a repeatable, consistent performance of the extrusion lines. The implementation of the revised methods resulted in a 15% drop in the overall defect rate, creating new company KPI records along the way.

The Results

• 12x the investment returned to the business

• Project payback period 1 month

• Two employees trained to Certificate IV in Competitive Systems & Practices

• Sustainable operations.

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