Rittal C S M Ltd

Background

Rittal-CSM is the largest manufacturer of industrial and data communication enclosures worldwide. Over 8,000 products are available worldwide. From standardized large enclosures to customised individual solutions.

Scope

A team of three people, Dave Bateson, Maurice Shreeve and Steve Royle, attended the SWMAS Six-Sigma Greenbelt Programme. As a 13 day programme interspaced with project work the Rittal-CSM team chose their project early on and worked on it through to their Greenbelt Certification.
Project: 100Kg Shelf Assembly

Method

The project team defined the current state of the process and found:

• High Customer Complaint and return of Shelf Assembly
• Work Area with room for Improvement
• Variable Process methods

Project Goals:

• Identify and eliminate Process Variables
• Improve Performance to Customer
• Standardise the Process
• Reduce Returns and associated Rework
  
  Utilising the Define, Measure, Analyse, Improve and Control methodology of Six-Sigma the Project Team used the key tools and techniques to define the problem, analyse the process and identify the variables that could be controlled and improved.

Options and Recommendations

• Changed to tooling and orientation to provide better and more consistent results eliminated bouncing problems
• Workplace Organisation and Layout improved within the Cell
• Introduced clear Visual Standard Operating Procedures (SOPs)
• Introduced Quality Management Inspection Plans and run charts into the process
• Improved TPM for the equipment within the Cell
• Improved Visual Management and Performance Data within the Cell
• Record and Display Training Records within Area

Results

• Identified and removed Process Variables
• Standardised the Process (Introduced SOP's
• Awareness and Control of Quality from the Cell
• Improved working environment
• Significantly Reduced Rework and associated cost
• Improved Customer Satisfaction
• Secure future Customer Business

Further Actions

• Continue to develop Operator Training
• Continually monitor process
• Apply controls to other products
• Ensure Process Capability for new equipment to be introduced

Customer Feedback

"The programme was extremely well run and presented in a logical format. Although the project seemed easy to resolve, it was found that this was not the case and the tools and techniques taught during the programme, became invaluable in the resolution of the project. The resolution has now eliminated any rejects and customer concerns over this issue"