North American Lighting
General Description
- At the request of Nissan Motors, TPT dispatched a team of Quality Engineers to work on site at NAL to determine the root cause of numerous quality defects they were experiencing on head light assemblies.
- TPT provided three seasoned Quality Engineers to rapidly assess the current state process shortcomings and implement corrective actions to improve first time through quality
Scope
- Conducted time studies to develop baseline for process optimization activities and manpower reductions
- Development of current state standardized work sheets and Yamazumi charts for analysis and the reduction of waste
- Conducted root cause analysis activities with the plant staff to ensure sustainability of the transformation process
- Created the future state, standardized work sheets and Yamazumi charts which included waste reduction, quality improvements and optimized process recommendations
- Developed and supported a training program for the installation of the optimized processes for future state
- Supported the implementation of the new optimized processes and layout
Success
Within 6 weeks, the TPT QE team identified the root causes of the majority of NAL quality issues and implemented corrective actions for sustainable results
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