Process Improvement

Design of Experiments
To further understand why during a process, we have erratic outputs, we follow the concept of Designing Experiments to detect the source of the process inconsistencies. This event is referred to as "Design of Experiments" (DOE). Montgomery, D. C. (1991) notes that "A designed experiment is a test in which some purposeful changes are made to the input variables of a process or system so that we may observe and identify the reasons for changes in the output response. ... Experimental design methods play an important role in process development and process improvement."

At Pyramid Consulting, Incorporated (PCI) our staff will use Factorial Analysis that consist of Software Simulations, and use of STATISTICA applications when pursuing DOE. This can all also lead to the following:

  • Design for Cost (Cheaper)
  • Design for Quality (Better)
  • Design for Cycle Time (Faster)

Other applications will consist of geometric principles to statistical sampling to obtain desired results such as minimizing the number of experiments necessary to obtain the answer to a problem or minimizing the variance of estimated coefficients obtained through regression.

Ergonomics
With the ever-growing emphasis on Safety within the workplace, Ergonomics has become an important topic of discussion within employers as well as employees. With the implementation of Ergonomics, Pyramid Consulting, Incorporated (PCI) can help you, the customer improve workstations to better suit the worker. Some of these Ergonomics solutions can be small, but in return can have a great effect on the performance and efficiency of the workplace.

At PCI, our professionals can develop “Return-to-Work” programs that are cost effective and efficient. Under our “One-Stop” e-Portal, we are able to team up with other divisions of PCI to ensure the best solutions to meet the needs of our customers. Where applicable, PCI will team up with Chiropractors to ensure the most effective and efficient solution.

At first, PCI would provide an audit of the workstation. This would be in reference to a “Design Review”. Where is the disorder and how it came about? Then our professionals develop a successful ergonomics program to fit your environment. This environment can consist of a manufacturing line, a non-office location, or an office location. We would provide brainstorm sessions with the customer to ensure that the best possible program is implemented. Sometime this could consist of just educating the workers on the proper use of the tools around their workstation.

Motion and Time Case Studies
The purpose of Case Time Studies is to bring about complete elimination of waste. Which in return increases profits, reduced cycle time, and even quality improvement.

At Pyramid Consulting, Incorporated (PCI), we would designate a staff just for the purpose of providing you with such a Motion and Time Study. We would begin with an Audit of the process line you wish to achieve complete “Elimination of Waste” and “Improvement” on. This audit would consist of actual Stopwatch readings of each process and at the same time, videotape if approved. The entire “Case Study” would consist of the following:

  • Objective
  • Scope
  • Methodology (Flowchart)
  • Findings
  • Conclusions

Statistical Process Control (SPC)
What exactly is Statistical Process Control (SPC)? SPC is a method that reduces your production costs and gives your company even better control over striving quality standards. As a company, SPC can help you:

  • Keep track of your process, and make adjustments before defective parts are produced
  • Detect or identify causes of defects

Why SPC?
There are many benefits to using SPC, some of which have a direct, positive impact on you. Generally, SPC means:

  • Less cost to make a product
  • Less reworking of the product, and less need for inspection
  • Less scrap and waste
  • Detect or identify causes of defects.
  • Higher quality, yields, and productivity
  • Satisfied customers (whether they be the consumer, or the next person down the manufacturing line from you)

But, equally importantly, SPC gives you:

  • More of a sense of control over the process, and your workstation
  • A more interesting and challenging job
  • An expanded role in the making of a product
  • Guideline towards Six-Sigma

Six SigmaTM and SPC
How is Six Sigma associated with SPC? Well in order to achieve Six Sigma, you need to use statistical methodologies. The primary tool implementing “Six Sigma” is the use of the “Control Chart”. In general a control chart is a tool of SPC. In a control chart you have reference lines, called control limits, which are calculated based on the data in the chart, in such a way that very few points will fall outside the control limits as long as the process is producing consistent results.

Six Sigma technically means a failure rate of 3.4 parts per million; however, the term in practice is used to denote more than simply counting defects. With Continuous Improvement an ongoing quest for a vast number of companies, we at Pyramid Consulting, Inc. (PCI) strive to be your “One-Stop” e-portal to fulfill that quest.

Without implementing SPC and eventually striving towards Six Sigma, the goal for virtually defect free processes is extinct. As a matter of fact, Six Sigma is so important now than ever, that Motorola has developed the Six Sigma Black Belt level of expertise.

The Six Sigma implementation projects can cost on the average of $85,000 to $185,000 in value through the improvement of cycle time, reduction of defects, cost reductions, etc.

Since PCI is an official WonderwareTM Systems Integrator, we can develop the proper SPC guidelines to fit your needs along with the proper software packages. Our staff utilizes the PCI “One-Stop E-portalTM” concept to implement the best strategy for you to ensure that highest results.


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