Manufacturing Plant
Situation A manufacturing plant was suffering from excessively high in-process scrap rates (6.8%) in the zinc smelting department. Although the raw material could be re-melted and salvaged, the labor costs were excessive and on-time product deliveries were at stake.  Actions To remedy the inefficiencies in the manufacturing process, the company called on MetaExpert Michael. Micheal led the company through analysis. They studied the data and found that the root cause of the problem was with two-part numbers coming from two die-cast machines.  Furthermore, Michael studied the parts and his efforts and attention to detail in the manufacturing processes led to the discovery that the tools used were not properly vented. This caused porosity in the parts which resulted in the high in-process scrap rates. Results MetaExpert Michael’s experience in manufacturing processes and keen eye led to both tools being repaired at a cost of less than $15,000 each. The root…
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Evaluating Indirect and Direct Factors for I.40 ROI
“Think of the tangential benefits from the Space Program” In July, the World celebrates the fantastic Journey that Apollo 11 performed in 1969 when the first men were sent to orbit the Moon. Just think of what has happened as a result of the single-minded goal of putting a man on the Moon. At that time, the total computing power needed for that effort was less than the computing power of a smartphone. The main computers that powered the Apollo 11 mission were the size of four refrigerators!  Most likely, the majority of us don’t remember the protests at the spending ($40 billion for the entire 12 years of the NASA Man-on-the-Moon project), but looking back, just look at the unforeseen benefits of the digital age. Technology has shown itself to have the capacity of producing exponential ROI …in hindsight. The Investment of Industry 4.0 When considering the important investment…
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excavators construction quality control
Situation A building and construction company brought MetaExpert Alan onboard to help sort out operational and logistical inefficiencies regarding the construction of metal structures. The company was facing a 100% sorting and rework rate of their products after manufacturing. In addition, as a result of the focus on inspection after product completion, rather than during production, deliveries were delayed. Actions To remedy the construction company’s quality control issues and delivery delays, Alan took the following measures: Reviewed with the team all applicable specifications to ensure all employees understood the requirements Deployed the requirements to Key Process Control Parameters, not just final quality control Developed the processes to be robust according to the requirements Implemented control plans Audited process parameters and key characteristics, not just final goods Results Through his initial assessment, Alan was able to determine that a lack of communication and too many “experts in the room” was a…
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Automotive Giant Back on Top with MetaExpert Help
Situation A multi-billion-dollar tier 1 company became involved with a customer regarding a safety issue in which the customer was accusing the supplier to be at fault, thus revoking all 3 supplier manufacturing site locations for Q1.  This put the tier one supplier on new business hold and at risk of losing additional business they had plus additional quoting of new business opportunities. The company reached out to MetaExpert Jack for his APQP Process understanding, Advanced Critical Chain / Critical Path Methods knowledge, 5S and Standard Work expertise.  Actions Jack guided the organization to meet the challenge and improved productivity and facilitation of quality training and awareness. A collaborative cross-functional team of production, purchasing, engineering, and management was formed and led through a decisive 1-year plan, which involved the customer. This allowed for all key milestones to be met such that Q1 customer endorsement letters and Q1 site certifications were…
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War for Talent
Terms like innovation, transformation, and re-inventing are all common management jargon and aspirations. With the amazing new technologies transforming business models and the way businesses are planning for the future, there is a constant battle hunting for and recruiting talent that can bridge the gap between what was and what is needed to stay competitive. Note that talent does not necessarily mean a singular person. In fact, it is very difficult to find all the qualities needed to fit the definition of “Top Talent” in just one single person. Many think the War for Talent is all about technical capabilities such as computer engineers, software developers, and specialists in artificial intelligence. While this is partially true, there is an even more pressing need: Talent that can understand not only what new technology is MOST appropriate for helping to re-invent the company but also how to implement the changes necessary. Over…
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