With Synergy 2000 SPC Software Halla Reduced Scrap Rate by 80%
Executive Summary: Halla Climate Control Canada is a leader in the production of underbody refrigerant and coolant lines, accumulators/receiver driers, blower units and clutch components used in automotive air conditioning compressors. Every system they manufacture is custom- designed for each specific model of vehicle, producing a unique set of dimensions, configurations and performance requirements related to quality.
Case Study | Automotive, Case Studies, Industry, Management, Quality Assurance, Resources, Role, Software, Synergy 2000
The Challenge
- Reduce Parts Per Million (PPM)
The Solution
The Results
- Reduced PPM from 50 to 10
- Reduction in data entry errors
- Useful data collection for industry specific reports
- 80% reduction in scrap rate
The Details
Halla Climate Control Canada is a leader in the production of underbody refrigerant and coolant lines, accumulators/receiver driers, blower units and clutch components used in automotive air conditioning compressors. Every system they manufacture is custom-designed for each specific model of vehicle, producing a unique set of dimensions, configurations and performance requirements related to quality.” We specialize in automotive air conditioning components,” said Dan Corrigan, Operational Excellence Manager.
“Using the data from Synergy and a lot of hard work, we have been able to reduce our PPM (Parts Per Million) from 50 to 10. Synergy highlights for me what I need to do next. It shows me where the process is out of control, so we can address it.
— Dan Corrigan, Operational Excellence Manager for Halla Climate Control Canada
With a total of more than 500 employees in 2 plants, many of whom have to enter data 3 times a shift, Halla cannot afford data entry errors. With Synergy it doesn’t have to. “The system is very user-friendly. The team members can go up and call up their databank for a part. With the click of a button, they can input the data. No mistakes are made on entry because the system prompts the team member right on the spot,” said Corrigan.
With reporting requirements from AIAG (Automotive Industry Action Group) as well as the requirements of his customers, Corrigan needs Statistical Process Control (SPC) software in which data can be easily extracted. “With the Synergy SPC software, we have the data we need to meet these reporting requirements,” said Corrigan.
Prior to Synergy, Halla was using a manual process for SPC reporting. Their biggest success has been in the end-forming area, where they create the couplings that will eventually be crimped to the hose. It was an area where they previously had constant issues every shift: non-conforming products, scrap and rework. About three months after they implemented the Synergy 2000 software, they saw the scrap rate drop off. They improved by at least 80%, and rework dropped off as well.
With the help of Synergy, Halla has been able to transition from a paper system to a online SPC system, save time in transcribing the data, and highlight problems on the shop floor. “Using the data from Synergy and a lot of hard work, we have been able to reduce our PPM (Parts Per Million) from 50 to 10,” said Corrigan. “Synergy highlights for me what I need to do next. It shows me where the process is out-of-control, so we can address it.” Corrigan said they currently have an initiative to drive for Six Sigma 1 PPM and that Synergy will be instrumental in helping them get there.
“With Synergy, we have the data we need to meet our AIAG (Automotive Industry Action Group) and customer reporting requirements.”
— – Dan Corrigan
Operational Excellence Manager for Halla Climate Control Canada