Goals 1.Reduce inventory 25% 2.Improve productivity 25% 3.Create Standard Operations September , 2005 Quality Control Lab Kaizen Event

Baseline Metric: People Flow 320 ft worth of movement !!

Takt Time Chart Takt Time = 620 minutes = 525 seconds 71 Tests

Trial Setup Denier Coherency Instron T.S. WIP Material Flow Exit Operator One Operator Two Operator 3

New Cellular Layout Before Layout

Summary of Achievement MeasureBeforeAfterImprovement Operators per Shift 5420% Inventory % Movement per Test 320 ft60 ft81% Tests per Shift % Equipment Used % Material Flow Intersecting, colliding One direction, flow Goal is 71

Trial Results Computer issues disrupt ability to meet Takt Time TAKT TIME

Six Sigma: Reducing Variation Network too slow Re-Test procedure causing extra tests Eliminated unnecessary test Mistake-proofed sample log screens Coached adherence to standard operations across all four shifts Separated log screens to minimize file open/close time Achieved Target of 71 Tests!

Sigma Kaizen Event Reduce Fray Defects by 50% March 28 – April 2, 2005

Define and Measure Charter Defined defect as broken filament High level process map Detailed Quality Map Gage R & R on measurement systems Fish bone diagram to determine cause and effect Difficulty impact matrix Process Capability Comparative Analysis

Visual Inspection Gage R & R Results Within Appraisers Assessment Agreement Appraiser # Inspected # Matched Percent 95 % CI Brenda (60.03, 90.72) Vic (53.25, 86.25) Chris (53.25, 86.25) Katrina (56.60, 88.54) Edgar (56.60, 88.54) Sue (16.12, 50.01) # Matched: Appraiser agrees with him/herself across trials Repeatability Goal should be > 90% correct decisions! Between Appraisers Assessment Agreement # Inspected # Matched Percent 95 % CI (9.28, 39.97) # Matched: All appraisers' assessments agree with each other. Reproducibility

Visual Inspection Gage R & R Results No operators met the gage R&R goal of 90% Visual expert was only 62% repeatable! Completed parallel study using automated defect counter Gage results met 90% goal Through MSA, determined good product was labeled defective.

DMAIC at Kaizen Speed Project Charter to Implementation completed in 6 weeks! Kaizen Team process helps buy-in and sustainment Improved yield 2.5%! Traditional Black Belt Project Kaizen 9 to 12 months 6 weeks