Lean & Lean/Six Sigma Case Studies
Case study for external failure analysis - How does Omnex do it?
Find out in this case study
Click on image to enlarge
Click on image to enlarge
The future state would require breakthrough improvements. In order to begin the
improvements, Company X and Omnex agreed that the initial focus would be to streamline
the FA Lab and revise the process to complete the 7-step Corrective Actions once
the Failure Mode was determined.
In order to improve the FA Lab process performance, a three-step plan was developed.
Streamlining the FA Lab
Omnex established a plan to reduce the FA Lab RMA backlog. The Program Managers
were instructed to notify their customers and determine which products could be
sampled during analysis rather than every part. The FA Lab Supervisor was instructed
to only perform failure analysis on the backlog. Engineering was instructed to perform
failure analysis using their own Engineering Technicians on all incoming products
as of a particular date. The FA Lab Supervisor began reporting the backlog performance
of the FA Lab and Engineering on a daily basis to the Quality Director and to Omnex.
Omnex established a plan to improve the competencies of the FA Lab and Engineering
technicians. In order to improve these competencies, it was necessary to develop
a process to collect and share the technicians' technical knowledge. This would
ultimately improve the quality of analysis and reduce the lead time to assign failure
modes. Company X decided to develop a Visual Basic program that would instruct technician’s
step-by step which tests to perform in order to reach the correct failure mode.
The program time stamps each step of failure analysis so a standard time may be
established and individual technician performance may be measured.
Omnex developed a technician scheduling tool so that the FA Lab Supervisor could
plan each day's work. The FA Lab's new objective would be a 24 hour turn-around
for determining the failure mode. The Supervisor would be able to determine when
Customer Returns would be delivered to the FA Lab and could then notify the Quality
Director (his supervisor) when he predicted he could not meet his objective.
Within six months of initiation, the result of this plan will be zero overtime dollars
spent in the FA Lab for failure analysis and a zero RMA backlog.
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