1. Goals 1.Reduce inventory 25% 2.Improve productivity 25% 3.Create Standard Operations September 15- 19, 2005 Quality Control Lab Kaizen Event

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

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

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

5. New Cellular Layout Before Layout

6. Summary of Achievement MeasureBeforeAfterImprovement Operators per Shift 5420% Inventory 653442% Movement per Test 320 ft60 ft81% Tests per Shift 426131% Equipment Used 141029% Material Flow Intersecting, colliding One direction, flow Goal is 71

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

8. 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!

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

10. 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

11. Visual Inspection Gage R & R Results Within Appraisers Assessment Agreement Appraiser # Inspected # Matched Percent 95 % CI Brenda 32 25 78.13 (60.03, 90.72) Vic 32 23 71.88 (53.25, 86.25) Chris 32 23 71.88 (53.25, 86.25) Katrina 32 24 75.00 (56.60, 88.54) Edgar 32 24 75.00 (56.60, 88.54) Sue 32 10 31.25 (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 32 7 21.88 (9.28, 39.97) # Matched: All appraisers' assessments agree with each other. Reproducibility

12. 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.

13. 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