Improvement of Manufacturing Line Fill Rate

Abstract

Poor fill rates at manufacturing line for models 5038 and 4968 are problems that affected the cost metrics due to overtime and unsatisfaction of our patients around the world. The main cause of this problem is high lead time and waste during the operation process. The processes in the two manufacturing models 5038 and 4968 were studied in an effort to reduce the operational waste during manufacturing process, reduce or eliminate the overtime, reduce the lead time for both models and create pull system. Applying the DMAIC methodology, the fill rate was improved from 64.3% to 93 % by reducing operational wastes, reducing lead time, and creating pull system that will allow cost saving around $15,000 and improve patient satisfaction. Key Terms ⎯ Fill Rate, Lead Time, Models, Medtronic.