Promoting Continuous Process Improvements Leads To Reduction in Product Variation

This paper represents a case study in variation reduction of brake pad insulators. Process variation reduction requires us to view all aspects of the manufacturing process throughout the supply chain and define each aspect's contribution to variation in the product. In this paper, examples of problem solving and quality improvement tools utilized to identify sources of variation will be provided. In addition, using alternative statistical techniques and measurement methods, such as an Individual and Moving Range/Range Chart instead of the widely used Average and Range Chart, provide dramatic advantages for continuous improvement and yield a tool for tracking progress and process stability, as well as, provide evidence that process improvements greatly impact product variation.