YPSILANTI, Mich. - More than a year ago, a team of Rawsonville employees started the rework strategy for rerunning end caps through the MAD (Motor Assembly Dial) dial on the PM2 Starter line. The goal of the project was to avoid scrapping out thousands of end caps.
The team, made up of hourly and salaried employees across Starter, Quality and Engineering, identified three potential failure modes that needed to be addressed. Over the past year, the team implemented several precautions to protect these failures.
Today, the MAD dial on the PM2 Starter line has a less than one percent fall out rate and saved an estimated $6,831. With this regression process, the savings from the team’s failure protections will continue to rise. The team came together to go further and solve a problem that resulted in a cost reduction for the plant and for the company.