Trane, a leading supplier of indoor comfort systems, reported that it used WinSPC to keep its processes under control and reduce scrap by 50% annually.
Background
–Stan Crockett
Black Belt Engineer
Trane
The Trane Company, a subsidiary of Ingersoll Rand, employs over 29,000 people at 104 manufacturing locations in 28 countries, and has annual sales of more than $8 billion. Trane is a leading supplier of indoor comfort systems. It’s products include heating, ventilation, and air conditioning equipment for residential and commercial applications. Trane has gained significant benefits using WinSPC.
Challenge
For Trane, manufacturing leak-free refrigerant coils without generating an unacceptable amount of scrap is imperative to producing world-class indoor comfort systems. Trane was experiencing an unacceptable scrap rate in the process of fabricating these coils. Trane, therefore, set a goal to reduce scrapped coils and the copper and aluminum components that make up a refrigerant coils.
Using Six Sigma, Trane pinpointed the critical process inputs that have the most impact on improving quality and reducing that variation that causes coil slab and copper scrap. But significant challenges still remained.
Since Trane’s operators rotate frequently among various processes and machines, Trane recognized the need to keep operators continually up-to-date on a host of process issues, machines, and specifications.
Trane also wanted to ensure that all the benefits achieved through the Six Sigma process would be sustained through reliable control methodologies.
Implementation
Trane chose WinSPC for the following reasons:
- WinSPC supports Trane’s Six Sigma programs with essential data collection, analysis, measurement, and control tools
- With WinSPC, Trane was able to quickly train operators by supplying setup and operating instruction as well as blueprints and digital pictures; all as live documents and media that update in WinSPC as you change the source files.
- WinSPC offers a plant-wide monitor option that enables viewing of any process from anywhere in the plant at any time for optimum supervisory control.
Results
WinSPC supports Trane’s Six Sigma program by providing essential tools and ensuring success in the final control stage of the DMAIC cycle. Trane’s operators also have adopted WinSPC as mission critical to their success.
Benefits
Trane specifically cited the following benefits achieved with WinSPC:
- Reduced annual scrap cost by 50%
- Attained ROI in 4 months
- Significantly improved first-pass yields
- Instilled greater operator pride
- Sustained Six Sigma improvements through ongoing control
About DataNet Quality Systems
DataNet Quality Systems empowers manufacturers to improve products, processes, and profitability through real-time statistical software solutions. The company’s vision is to deliver trusted and capable technology solutions that allow manufacturers to create the highest quality product for the lowest possible cost. DataNet’s flagship product, WinSPC, provides statistical decision-making at the point of production and delivers real-time, actionable information to where it is needed most. With over 2500 customers worldwide and distributors across the globe, DataNet is dedicated to delivering a high level of customer service and support, shop-floor expertise, and training in the areas of Continuous Improvement, Six Sigma, and Lean Manufacturing services.