Case study · Mining & Metals
Metals processor raises plantwide yield from 38% to 55%
A large metals processor was losing material to scrap in bonding, annealing and slitting. USC applied a Lean Six Sigma yield method with cross-functional teams across all three processes.
Results
55%
plantwide yield, up from 38%
Gains came from the bonding mill, annealing and slitting.
The situation
The processor needed better quality from its bonding mill, annealing furnace and slitting line to raise plantwide yield.
What the assessment found
- Significant scrap from the bonding mill
- Material waste in annealing despite strong bonds
- Slitting defects scrapping whole bobbins
- Much of the slitting loss traced to operator error
How the work was done
Define: set the yield goal
Defined each problem with statistical analysis, set goal metrics and mapped bonding, annealing and slitting from cradle to grave.
Teams: own the fixes
Formed cross-functional teams with clear leads, who learned the tools to carry the work forward after the project.
Control: lock in the gains
Executed focused corrective actions in each process and put controls in place so the losses wouldn't return.
55%
plantwide yield, up from 38%
Before and after
Plantwide yield
+17 pts
Plantwide yield.
Lasting impact
Yield rose across bonding, annealing and slitting, and the processor's own teams learned the method to keep improving.
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