Fuel Pump

Fuel Pump Practice / Industry: Automotive Challenge A fuel pump manufacturer needed to develop a new fuel delivery system to satisfy hot fuel handling requirement. In order to reduce pollution, the company needed to develop a new system which delivered precise fuel flow for combustion so that they could eliminate unused hot fuel returning back to the fuel tank. A team of engineers was assigned to accomplish this in three years. Two years into the assignment, they could not meet the requirement. ASI Solution To attack this fuel pump problem, ASI Consulting Group was asked to help with robust optimization strategies. After two months, the developer had a design that met all requirements. Achieved Benefit The [...]

By |2018-07-08T04:14:27+00:00October 16th, 2015|
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Window Closing Effort

Window Closing Effort Challenge: A high volume automobile had a problem with window closing effort. While the ideal value for window closing is 12.5 in-lbs, both right and left side windows were averaging around 20.0 in-lbs, which caused multi-million dollar warranty costs. ASI Solution: The window closing effort problem presented many interesting and serial problems. ASI Consulting Group recommended optimized tolerances of components around the door assembly and window regulator. Achieved Benefit: The team finished tolerance design in two weeks. As a result, tolerance of two components was adjusted and window efforts were reduced to approximately 13 in-lbs. There was a multi-million dollar reduction in warranty costs.

By |2018-07-08T04:15:49+00:00January 12th, 2015|
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Strategic Quality Focus Nets 100 million

Strategic Quality Focus Nets 100 million Practice: Strategic Quality Focus Challenge A multi-billion dollar automotive supplier was on the brink of losing its OEM customer since it was unable to meet its quality requirement. They sought a strategic quality focus to increase their quality levels and asked ASI Consulting Group to help. ASI Solution After our first analysis, it was clear to the team that the company needed to implement DFSS in order to reach their strategic quality focus. ASI's Subir Chowdhury developed the concept in his 2005 book, "Design for Six Sigma." ASI has maintained a high-level understanding of implementation and requirements. We conducted a comprehensive review of the client's quality practices and developed an implementation [...]

By |2018-07-08T04:17:04+00:00January 12th, 2015|
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Software Testing

Software Testing Challenge: Software testing is a time-consuming process for any company who develops software systems. A $5B company produced electronics for defense systems. One particular product used for an electronic warfare system was taking 40% of development time for software testing which needed to be reduced. ASI Solution: For the procedure to be robust, software testing should be designed by experts. After our initial consultations and meetings, ASI Consulting Group made several recommendations. First, we suggested that the company develop a totally new approach. Second, we felt that robust testing didn't necessarily mean longer testing. The optimized software testing procedure reduced testing time by more than 75% as compared to the traditional software testing, without deteriorating [...]

By |2018-07-08T04:18:49+00:00January 12th, 2015|
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Six Sigma: ASI Helps Heavy Equipment Supplier Navigate Market Downturn

Six Sigma: ASI Helps Heavy Equipment Supplier Navigate Market Downturn Practice: Six Sigma Challenge The Company was in a significant downturn: revenues were decreasing, profit margins were plummeting and new product releases were less than desirable. ASI Solution Based on their own research, the company sought a consultancy that was a proven Six Sigma expert. ASI was brought in to consult on both product and process improvement and also transactional process improvement. This large undertaking was a very ambitious program for a six sigma implementation. The transactional processes were found to have a large source of untapped waste removal. The new products were being development and released without the benefit of Robust Engineering methodologies. By utilizing [...]

By |2018-07-08T04:20:07+00:00January 12th, 2015|
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Service To Cash Improvement

Service To Cash Improvement Challenge: Claims submitted to insurance providers resulted in an unacceptable level of denials. In these cases, service to cash transactions were breaking down. Services were provided but were either not paid for, or were paid at a level less than expected. This led to lost revenue and excessive time spent following up on denials. The objective was to reduce the number of denials and act upon remaining denials quickly, resulting in increased revenue and shorter collection. ASI Solution: Analysis of service to cash, in particular the denials, revealed that required information was often missing from billings; providers had not been adequately challenged in some denials and people submitting billing often coded in [...]

By |2018-07-08T04:21:31+00:00January 12th, 2015|
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Robust Engineering Assists Product Complaints

Robust Engineering Assists Product Complaints Practice / Industry: Robust Engineering Challenge Development of a vision based method for classifying occupants in the passenger seat of automobiles. The federal government placed requirements on when passenger side air bags can deploy, requiring the system to be able to detect and classify occupants. Although the company had an existing method of classification, they were trying to explore new technologies that would increase the Robustness of the classification. ASI Solution After our initial assessment, it was decided that the company needed robust engineering to improve the process. ASI Consulting Group executed a pattern recognition system called MTS. Achieved Benefit The team completed the study of the current and proposed technology and [...]

By |2018-07-08T04:23:23+00:00January 12th, 2015|
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Robust Engineering Facilitates Firm’s Entry Into Virgin Market

Robust Engineering Facilitates Firm's Entry Into Virgin Market Practice / Industry: Robust Engineering Challenge The firm's marketing division has identified that the market for compressors for water coolers and mini refrigerators was increasing. The company was eager to capture this new market. Presently it did not have any models for this segment of the market. ASI Solution The firm decided to come out with a design comparable with the best in the world, which at the same time would be cost-efficient. The company benchmarked itself with the leading compressor manufacturers. Seven design variants were selected and each varied at two levels. Robust Engineering methodology was used. Achieved Benefit Robust Engineering helped the company to incorporate the [...]

By |2018-07-08T04:24:49+00:00January 12th, 2015|
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Power MOSFET

Power MOSFET Challenge: A power MOSFET is used in automotive electronics as a reliable switching device. An increase of electronics creates resistance to reduce power dissipation within. In general, on-resistance of the power MOSFET is reduced by miniaturization of unit cells. This team was task however, with reducing on-resistance by improving the drain electrode process. ASI Solution: ASI Consulting Group optimized the design of the MOSFET drain electrode. Achieved Benefit: The improved robustness of the electrode drain allowed for an annealing process to be eliminated. Because the annealing is eliminated, all defects from annealing were eliminated. Because there is no annealing, the substrate can be thinned further, which leads to a reduction of resistance that is [...]

By |2018-07-08T04:26:23+00:00January 12th, 2015|
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Paradigm Change In Approach Through DFSS

Paradigm Change In Approach Through DFSS Practice / Industry: DFSS Challenge An automotive supplier was facing an intense pressure to reduce emission from its fuel handling system. Many of its previous efforts to confront this problem failed. This was of strategic importance to the company and ASI was called for its expertise to solve this problem. ASI Solution ASI worked with client's team of engineers to design an optimization strategy using DFSS. Within two months, a design that met all requirements was executed. Achieved Benefit Our implementation of DFSS translated into substantial cost savings of several million dollars. The future warranty cost avoidance also contributed several million dollars.

By |2018-07-08T04:28:08+00:00January 12th, 2015|
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Quality Consulting ASI Consulting Group: Global leader and pioneer in Quality Improvement for more than 30 years, specializing in Six Sigma, Design for Six Sigma (DFSS), Quality is Everyone’s Business (QIEB), Robust Engineering, Lean standards and Listen-Enrich-Optimize (LEO) | Call: (248) 530-1395. All Content © 2013 ASI Consulting Group. All Rights Reserved.

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