Improve your quality by analyzing the operating data with statistical tools.
You are literally flooded with all the data collected during the manufacturing process. But how do you determine what data is useful and valuable for improving your production performance and conducting root cause analysis? Using Statistical Operational Data Analysis “SODA” we combine the data into a data cube and analyze it with sophisticated statistical tools. This reveals formerly unknown interfaces and can be used for in-depth root cause analysis. This allows problems or quality defects to be identified and remediated. SODA was developed by our consultants as an innovative addition to the existing approaches in our Targus Toolbox.
A small leak can sink a great ship
The SODA Tool follows the statistical footprints. (Link to Website TARGUS SODA) It uses the treasure trove of data compiled in modern production facilities. The resulting data has a dual purpose: First in its intended purpose and second for statistical data analysis. Based on this evaluation direct approaches for quality improvement and cost optimization are developed.
Example: cost reduction by 30 %
A client in the automotive industry observed sporadic and strong deviations in quality in his manufacturing plant, resulting in high costs. Using the SOBA tool the root cause of this issue were isolated, remedies developed and scrap rate declined.
To do this we utilized the available data. We especially analyzed the scrap data per
- Assembly part,
- Exact time
- Parameters of the equipment, Press capacity, Oil temperature, Location of the equipment
including information regarding outside temperature and equipment operator.
By analyzing the data patterns, factors, cross correlations and repeating patterns were detected. Equipment near exterior doors had significantly higher scrap rates. The high scrap rates correlated to cold outside temperatures which caused cooling of the tools near open doors. This hypothesis was confirmed using the data and technical testing.
The remedies were:
- Fast opening entrance gates at selected sites
- Placement of heating elements for machines close to entrance gates
Using SODA a 30 % reduction in scrap rate was achieved.
Process of the SODA Tool Application
The Statistical Operational Data Analysis depends on the one hand on the experience of the employees and on the other on the analysis of the data. In rapid cycles the data analysis and the technical experts are consulted. This repeatedly produces new areas for further analysis – until the root cause is found.
Steps of SODA
1. Results of analysis serve as starting point
2. Hypotheses are developed and documents in teams
3. The resulting tasks are prepared by teams (Data requirements, Testing, Measurements)
4. Using the hypotheses the data module is expanded using new data
5. The new hypotheses are tested in the data module)
The project takes four to five weeks in average. It takes the first two weeks to prepare the data and includes formatting, error and deviation identification, consistent testing and identification of variables. Thereafter the analysis itself begins using the parameters time, material, process and environment. SODA provides a clear indication of the necessary changes to improve quality and reduce costs.
Please do not hesitate to contact us. We use your data for a cost effective quality campaign.