Application of DMAIC Process for the Cycle Time Reduction in the Synergy COS line at MJC

Abstract

Simplera® is a Continuous Glucose Monitoring Device manufactured at Medtronic Juncos in 8 Cell Operating System. Using DMAIC methodology, the objective of the Capstone was to reduce by 10% the Cycle time of the Patch to Serter Process. SIPOC, VOC and CTQ analysis were performed to define the problem. Results for Time Study divided into 4-time elements (TE) were: 9.51s (TE 1), 15.64s (TE 2), 6.13s (TE 3) and 6.03s (TE 4). The highest element corresponded to the bonding process. The Overall Cycle time was 37.09. DOE study was performed to understand relationship between inputs (time and pressure) and output (Put Test; minimum of 2.9lbF). Analysis performed through the use of 5 whys and Fishbone tools identified process development without consideration of cycle time and inadequate line balance as main root causes for cycle time deficiency. Three (3) Proposed Solutions (PS) were identified and evaluated. PS1, new input parameters (77.5lb of pressure and 1 second of time), were identified through Optimization process using DOE information and statistical analysis of confirmation run (PPK 2.80). PS2, reduction of headcount, was identified through Line Balance exercise for Walkpath 1 to 3. PS3 was the simultaneous implementation of PS1 and PS2. Based on Simulation analysis, PS2 ($611,604.00 per year) and PS1 ($384,933.60 per year) were considered to have the highest profitability. Design Implementation and Control Strategy were defined to ensure the sustainability of the improvements.