Streamlining information and part flow by re-designing process flow to aid root cause analysis

Abstract

Waters Corporation is a world leading analytical instrument manufacturing company, with an overarching goal of achieving and maintaining high product robustness. Analysis of the challenge identifies the problem of lack of root cause analysis. This is further attributed to the inefficient process flow of information and parts: there is a lack of tracking mechanism for parts which is induced from lack of ownership and value at each stage of the root cause analysis phase. A new process flow is designed around the current process to address gaps and inefficiencies. This process flow redesign is done for both information flow for hot parts list and the movement of parts; this will streamline the overall root cause process and secondarily help save cost and eliminate redundancies. A layout improvement solution is developed, and a plan for implementation recommended. The new process flow is designed to increase visual control of the process and to effectively move the material. Each phase of the project has been reviewed and discussed to encourage stakeholder involvement in order to develop a continuous improvement culture.