Statistical process management: the implementation of a web-based process control system that drives significant cost, quality, and delivery gains in a large-scale manufacturing environment

摘要

At a large-scale Lucent Technologies manufacturing facility, the systemic implementation of a web-based process control system has facilitated substantial efficiency gains and fundamentally changed the culture of the operation. The system provides real-time graphical, audio, e-mail, and paging alarms to production associates and other subscribers. A SWAT team led by production associates, and supported by engineering, supervision, and the quality organization then mobilize and descend upon the production process in question to resolve the issue. Results are recorded and compiled to build historical information and target areas for improvement. Response times are monitored and given factory-wide visibility. The entire process represents a dramatic change from the pre-implementation mode of operation and manufacturing operations now realize near daily cost savings, quality improvements, and delivery breakthroughs. The session covers the evolution of this change, from concept to implementation, including: ·Overview of Concept ·Review of Manufacturing Operations and Quality Architecture ·Model Development, System Features, and Demonstration ·Management Proposals, Barriers, Trials, and Data to Verify Effectiveness ·Training, Awareness, and Implementation Effects of Implementation ·Summary of Keys to Success The session illustrates the results that can be achieved by combining technology and teamwork in a synchronized effort. The paper details an approach to performance improvement, shares actual results, and describes methods of analysis used to gage factory performance.