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Manufacturing Industry Success Stories BASF Corporation - BASF uses QualPro's MVT® to improve operations and reduce costs resulting in a savings of over $600,000 and avoidance of a $750,000 capital expenditure-A very competitive marketplace made it critical for the BASF Cyclohexanone I unit in Freeport, Texas to improve operations and reduce costs. Using MVT®, this 41-year old plant involved all four production shifts to make major process improvements with no capital investments. Increased production and improved yields were achieved, resulting in manufacturing savings of over $600,000 per year while avoiding a potential $750,000 capital expense. International Specialty Products (ISP) - Using MVT®, International Specialty Products (ISP) improved measurement systems and reduced variation for a key product capturing a $900,000 market opportunity. A million-dollar market opportunity was within grasp, but a new product application would require tighter control. Variation was the enemy that stood in the way of this new market opportunity. To control the enemy, ISP focused on MVT® methods to improve measurement systems and reduce variation for one of its key products. This product is used in pharmaceutical, electronic and industrial applications, each requiring a specific level of key measure. The trick is to be able to dial in the exact value needed. The key measure needed to be controlled from production through delivery to prevent variation. Using MVT® a $900,000 opportunity was captured. Pactiv - A manufacturer of packing materials had used QualPro's 12-Step MVT Process® to markedly improve its manufacturing process and wondered if it could breath new life into its sales process. Brainstorming sessions with sales people and account managers identified 120 possible factors that were reduced to 23 ideas to test. Three factors impacted the process positively. After only three months, the company had more than 120 new accounts worth millions in revenue and is on its way to a greater than 18% increase in sales during the first year of implementation. Elo Touchsystems - A manufacturer of touch screens widely used in automated control systems was suffering great losses in the conversion of raw materials into good, saleable flat and curved touch screens. The estimated yield was only in the 63% range. The company recognized the need to improve its production effectiveness in order to maintain its current customer base and participate in the explosive growth occurring in the industry. They turned to MVT®. The initial brainstorming produced over 80 ideas for improvement, of which 18 ideas met the practical, fast, and cost free criteria and were tested. The results showed that five factors significantly improved the yield for flat screens and two of the factors improved the yield of the curved screens. Process yield increased an astounding 28% from 63% to 91%. This $8 million per year improvement also allowed the company to capitalize on the expanding market and become one of the leading suppliers. Exide -- A larger manufacturer of power equipment, was having problems at one of its manufacturing locations. Yields on one of its products had dropped to 90%. Scrapping 10% of its production was not only a costly problem, but also represented a significant environmental issue with the subsequent disposal of the defective units. They turned to MVT®. During the brainstorming session, forty process variables were identified that might have an impact on the eight different failure measures. Of these, 20 were deemed practical, fast, and cost free. The MVT revealed that setting the factors at their helpful settings improved yield from 90% to 98%. Testimonial Video: Executives Describe Using MVT® to Improve Manufacturing Performance (38.6MB, .wmv) Request More Information about QualPro's Services Is MVT® right for you? Schedule a no obligation conversation with an MVT® Expert. |
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Since 1982, QualPro has used Multivariable Testing (MVT®) with 1000+ companies to test 100,000+ improvement ideas. MVT® tests between 20 and 40 ideas simultaneously, accurately predicting the bottom-line impact of potential process changes in weeks. Take existing process initiatives, like Six Sigma, to a whole new level. All process improvement tools and approaches (TQM, DOE, Six Sigma, Re-Engineering, SPC) can be enhanced through the use of Multivariable Testing by QualPro.
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