SPC Training Increases Productivity at Polymetallurgical Corporation
North Attleboro, Massachusetts-based Polymetallurgical Corporation (PMC) manufactures industrial-clad metals, bonding wire, and registered products: Palmet, designed primarily for the semiconductor industry, and Corelay, for coinage. PMC was established in 1972 and employs approximately 80 people.
During the company’s ISO 9000 registration process, PMC wanted to establish Statistical Process Control (SPC) in all manufacturing areas, so it contacted the MassMEP for help.
Implementing SPC
MassMEP conducted SPC training over a six-week period at PMC. The first level of training was an introduction to familiarize all 80 employees with SPC. The second level was an advanced program for manufacturing, sales, and engineering department managers. Each selected specific products on which to begin a complete SPC effort to improve manufacturing methods.
In the wire department, PMC implemented SPC tools on a high-strength, gold bonding wire production process and reduced raw material costs. In addition, the morale of PMC’s operations staff increased, due in part to employee empowerment and increased self-reliance. SPC produces data plots that allow operators in the specialty wire area to identify problems as they occur and initiate correction immediately. Thus, inspection time decreased and productivity increased. PMC’s key operators became totally committed to the process and are supported by the technical staff.
“Our high-strength gold bonding wire production process now manages itself,” said Fred Ty, Wire Processing Department Product Manager. “Our process capability index has risen from 1.27 in May to 2.14 in November. And the scrap costs have been reduced to an average of $190 per month, as opposed to $1,450 the company experienced before the SPC project. As you can see, the benefits of SPC to our group have been significant.”
Results
Reduced scrap cost from $1,450 to $190 per month
Increased employee morale and self-reliance
Improved productivity
Identified and corrected problems immediately
The MassMEP is an affiliate of the National Institute of Standards and Technology (NIST) under the US Department of Commerce. For more information on their services for manufacturing companies, see http://www.massmep.org, or phone 800-MEP-4MFG.
