Team #9: Siddarth, Henry, Suman, Jyoti & Rachael

BACKGROUND
KomTeK Technologies began operations in 1984 and is a precision closed die forging and investment casting facility supplying the
medical aerospace, nuclear, petrochemical and industrial markets. The company specializes in working with materials such as nickel
and cobalt based alloys, aluminum, titanium, high temperature alloys, hastelloy C & X, Inconels, and all stainless steels.
The problem faced
- higher scrap, it is usually standard scrap from 2% and 6% but in this case was 10% quality problems
- a lot of effort to rework
- Incorporate distal tip into the process
- Inadequate Distal tip reinforcement
- It was an unusually large order (Bob)
- Play a rush on the 811073 order

The standard cost per piece ratio raised from USD 53 to USD 63
PC Ratio decreased from 1.33 to 1.08
70% of the cost variations is caused by 10% of activities

CURRENT SITUATION
64.00
62.00
60.00

Standar Total Cost

NDT Facility (96% more 4.77)
Straighten (91% more 2.16)
Helper (35% more 0.90)
Alox 90 (29% more 0.41)
Visual (28% more 0.27)
Forge (9% more 1.20)
Quality control (18% more 0.22)
Others (0.07)

58.00
56.00
54.00
52.00
50.00
48.00
1

70% of the pieces were rejected in 40% of operations

KomTek need to improve the process in of NDT and Straightness
Exhibit 4 % of pieces rejected per operation

13%

4%
14%
Visual
Parting Line
Straighten
NDT
Quality Control

20%

49%

Fishbone Analysis
Cause
Machine

Effect
Material

Inadequate die set Reinforcement

Die overuse
Die not customised
Inexperience with handling large rush order

Insufficient stock of die

Straightening process
No procedure for
inspection
of old machineries
De-burring process

Human

Process

Reducti
on in PC ratio

RECOMMENDATIONS
The Following are our recommendation for Komtek to improve their PC efficiency
Improve die reinforcement quality
Customize new die set for distal tip
Change die after 1000 uses
Due to volatile order numbers Komtek should have a back up die at all time
De-burring Machine should be checked for too much pressure
Have the hot coin instrument calibrated for accuracy and checked for wear and tear, since its been used for years. Should be
replaced if found too faulty
Not ready for large volume order, should have processes in place to deal with large volume orders. Eg more labour during
high volume orders

Thanks You!!

We welcome any comments on our

subject

3. Which specific cause is contributing to the majority of scrap/rework?

(Bob). Specific at the non- destructive testing NDT Facility, straightening and quality control areas.
(Keith) Seems like we have been straightening almost 50% od them and I have a feeling that the distal tip is not handling the hot coin
hammering so well.
4. What specific policies/procedures should the Screaming Eagles recommend?
Recommend to redesign the process, if they are going to include a new feature into the product they should be sure first that it is going
to work with the machine that they have. (Keith: We have been using this instrument for years). But maybe it is time to buy a new
machine according to the real necessity.
To have checker before the last part of the process and they can correct on time.
They should build they are own Quality control because in the case I read that they send to outsorcing to make a control.
If they are going to

1. Why is the Zimmer order having such a low price to cost ratio?
There are many reasons
-. higher scrap, it is usually standard scrap from 2% and 6% but in this case was 10% quality problems
-. a lot of effort to rework
-. Incorporate distal tip into the process
-. It was an unusually large order (Bob)
-. Play a rush on the 811073 order
2. What are the primary sources of scrap/rework in the Zimmer order?
-. NDT Facility (96% more 4.77)
-. Straighten (91% more 2.16)
-. Helper (35% more 0.90)
-. Alox 90 (29% more 0.41)
-. Visual (28% more 0.27)
-. Forge (9% more 1.20)
-. Quality control (18% more 0.22)