Potting Process Improvement for Inductors

Abstract

During the last 20 years, X Aerospace Company has produced enormous gains due to a relentless focus on process in manufacturing, engineering and research and development. These margin increases came from many incremental and continuous improvements in all aspects of its business [1]. Continuous improvement has important benefits for corporate capital and cash flow requirements. The main goal for this project was to identify the main problem-taking place during potting operation, for an inductor that was not able to meet dimensional specifications. This project will use tools and methods adapted from lean, quality and statistical process control practices. The project led to a reduction of potting dimension out of specification condition by 100% and increased manufacturing yield by 13%. This huge opportunity was developed under the Define, Investigate, Verify, and Ensure (DIVE) cycle methodology, to identify real root causes affecting process yield and leading to unnecessary scrap and rework expenses. Key Terms - DIVE, Lean Six Sigma, Opportunity, Process Improvement, Quality, Yield.