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SixSigma improvement in rubber compound production

  • Too many changes to a well established process in the rubber compounding production have created an unstable system with 30% of product scrap, a profit loss of 0,5 mEUR per month
  • This company is in danger and asks to Growing to study the reasons of this instability and solutions to return to normal scrap rates. We launch a SixSigma project with design of experiments (DoE) and test production every day.
  • We identify the root causes and simulate the system in its original condition until we find the most sensitive process parameters and fine-tune those until an acceptable scrap rate. Additional weaknesses were: missing SOPs, shopfloor discipline and poor management