case study pdf

This Lean Six Sigma project focused on reducing First Pass Yield (FPY) scrap in aluminum machining components within a manufacturing environment. The production line was experiencing an average scrap rate of 8%, leading to material losses, rework, reduced productivity, and increased operational costs. Through a structured DMAIC approach, the project team identified critical root causes including tool wear, tool offset errors, setup variations, and machining parameter deviations. By implementing process standardization, preventive maintenance, operator training, SPC monitoring, Poka-Yoke controls, and waste reduction techniques, the organization significantly improved process capability and stabilized production quality. The initiative successfully reduced scrap variation, improved FPY performance, enhanced operational efficiency, and created a more controlled and sustainable machining process.     View Project Report