Success Stories

Aerospace

Problem
This Aerospace OEM wanted to create a supplier improvement program involving the application of statistics to low volume manufacturing processes.

Solution
Our trainers at PIC created a customer specific, customized training module. A five training module was created; two for statistical process control and three for designed experiments. All focused on short-run manufacturing and used real life aerospace examples. The benefit and solution to this training provided, helped suppliers experience significant decreases in process variation leading to lower scrap and overall lower cost of quality. The OEM experienced higher quality components leading to smaller tolerance stack.

Automotive OEM

Problem
This Automotive OEM was using a 3rd party inspection company who was repeatedly allowing escapes. In addition, this OEM required travel to a number of locations across the USA and the current provider was not able to support them. They called PIC, due to our reputation and our ability to service their needs in over 8 sparsely located locations throughout the USA.

Solution
The requirement was a minimum of 8 people at 8 different locations across the USA. Our inspectors needed to be certified to an automotive paint spec. PIC deployed 8 qualified resources, made hotel, airline and rental car reservations, to 8 different locations all within 24 hours. PIC then contacted the distribution centers, determined work schedules and start-up times, as well as handling all of the work instructions and inspection criteria. Given the extremely short notice, this OEM was not only impressed with PIC's responsiveness and cost efficiencies, but particularly impressed with the quality of our people.

Automotive Parts Manufacturer

Problem
This automotive parts manufacturer had just opened a new plant using a new process. As they ramped up for job 1 their first run rate dropped 2%. As the automotive parts manufacturer and their customers worked together to find a solution, they contacted The PIC Group.

Solution
We sent 100 inspectors and 30 engineers to assist them in improving their processes and quality. We achieved 100% inspection of every product and began error proofing their manufacturing and quality rates. Many of the changes we implemented are still used by this automotive parts manufacturer today.

Consumer Products

Problem
This customer was not only a provider of sports equipment to the consumer, but also to professional athletes. In launching new products for the professionals, they had plenty of time for “trail & error”, however, they needed to be more efficient in preparing new designs for the consumer markets.

Solution
A series of onsite workshops were conducted involving engineering, quality, manufacturing, purchasing, sales, maintenance and tooling. First, FMEA was applied to the product design and then the manufacturing process. Risk was estimated for all potential failure modes and corrective actions were determined and implemented. The next new product launch saw an increase of 'first time quality' of 70% and a decrease of 'time to market' of 30%. The customer immediately redeveloped their internal procedure for quality planning to include both Design and Process FMEA.

Industrial Parts Manufacturer

Problem
As a supplier of bolts and fasteners to customers throughout North America, they looked for a 3rd party inspection provider that had the expertise and geographic reach to quickly contain their issues.

Solution
In a weekend, PIC dispatched 120 people to assembly plants and distribution centers across the USA and Canada to clean the pipeline. PIC also sent engineers to many manufacturing plants to audit their manufacturing process. PIC personnel were trained on the proper OEM equipment and reported data on a daily basis to the OEM and the industrial parts manufacturer. Our engineers made recommendations that were implemented and we completed the project ahead of the original guild path.

Medical

Problem
The customer was experiencing a higher that usual rate of field failures and customer complaints on a newly launched EKG electrode.

Solutions
An onsite workshop was conducted at the customer site with all departments represented. The PIC Training Consultant took the group through each step in the classic 8 discipline approach; the skills were applied to the actual EKG issue. Three potential root causes of the EKG issue were identified, with associated corrective action. One was validated as the major cause, while another was proven as a secondary cause. Both corrective actions resulted in the elimination of the field failures.

Military

Problem
The armed forces 'industry' has historically been managed with very strict, and specific, military standards. Since the early nineties, these standards were replaced with ISO 9001 based systems. Systems that required auditing and supplier development. Most organizations in this field did not have the experience.

Solutions
Customized auditor training was developed for those responsible for internal auditing, auditing of military bases, auditing of suppliers and for lead auditors. The overall benefit and solution to our training - Consistency. All auditors were taught to audit following the same internationally recognized process. Audit results directed the auditees to the root cause of the discrepancies allowing for easier identification of permanent corrective actions.

Optical Products Manufacturer

Problem
This customer had designed and developed some of the finest, leading edge technology in their field. However, they were slow to market and often took a long period of time to perfect their manufacturing processes.

Solution
A series of onsite workshops were conducted involving product design and manufacturing engineering along with quality assurance and sales. Participants were taught proven methods for ensuring the voice of the customer is captured and maintained through product/process design, development and validation. A new product launch process was created at the conclusion of the workshops. The customer began experiencing a dramatic growth in business shortly thereafter and credits the new product launch procedure for much of their success. The testimonials from their customers continually use the same phrases, "consistent high quality and on time delivery".

Renewable Energy Manufacturer

Problem
This OEM needed a more robust and experienced solution, as they were used to using temporary labour or their own internal personnel.

Solution
With a few locations, but a huge fallout rate, this OEM knew they had to react quickly to contain defects. Within days, The PIC Group deployed 100 people at 6 different sites. We deployed our qualified personnel quickly and trained them proficiently to do the job, 24 hours a day, 7 days a week. The staffing for this project was a challenge due to a low unemployment rate, rural location and demanding hours. Our team had the experience, knowledge and resources to help this OEM contain their quality issues and find a long term solution.