Applying Lean Six Sigma & Technology to Maximize Uptime and Safety
By implementing a multi-pronged strategy combining robust technology (UniFi, Cradlepoint), an automated CMMS (eMaint), and Lean Six Sigma principles, we transformed the operational capabilities of the R&D and Field teams. This initiative directly addressed critical points of failure, resulting in a **95% reduction in downtime** from parts shortages and a **75% decrease in remote site troubleshooting time**.
| Metric | Before Project | After Project | Improvement |
|---|---|---|---|
| Downtime from R&D Parts Stockouts | ~20 hours/month | < 1 hour/month | 95% Reduction |
| Mean Time To Resolve (MTTR) - Field Network Issues | 4-6 hours (incl. travel) | < 1 hour (remote diagnosis) | 75% Reduction |
| Field Data Upload Success Rate (First Attempt) | ~55% (unstable hotspots) | >80% (stable connection) | Vastly Increased Reliability |
| Reported Safety Incidents / Near-Misses | 3 per year | 1 per year | 100% Reduction |
Phase 1: Define
The organization faced systemic downtime and safety risks across its R&D and Field Operations teams. The core problems were defined as:
Phase 2 & 3: Measure & Analyze
Initial data collection (Measure phase) confirmed the severity of the KPIs listed above. To understand the root causes, a Fishbone (Ishikawa) Diagram was used to structure a brainstorming session with key stakeholders from both teams (Analyze phase).
Phase 4: Improve
Based on the analysis, I designed and executed a multi-faceted project to address the identified root causes.
Phase 5: Control
To sustain the gains and ensure long-term success, control measures were established. This included the development and delivery of comprehensive Standard Operating Procedures (SOPs) for all new systems and the ongoing use of the eMaint CMMS dashboard to monitor inventory levels and usage trends. These controls prevent regression to the old, inefficient methods.
Client: Internal R&D / Field Operations
This project will engineer and deploy a robust remote monitoring solution to increase personnel safety, reduce diagnostic-related downtime, and improve management oversight at the R&D test facility. The current lack of visibility creates unacceptable safety risks and operational inefficiencies.
Client: Field Operations Team
The Field Operations team currently relies on unstable, consumer-grade personal hotspots, resulting in poor connectivity, failed data uploads, and significant lost time. This project will deploy an industrial-grade, dual-SIM cellular router to provide reliable, high-speed internet connectivity in the mobile trailer, enabling real-time data transfer and access to cloud services.
Client: R&D Operations Team
The R&D lab experiences frequent and costly project delays due to stockouts of critical consumables. The lack of an inventory system prevents usage tracking, forecasting, and timely reordering. This project will implement the eMaint CMMS to automate inventory management, eliminating stockouts and providing valuable usage data.
Purpose: To define the standard process for authorized personnel to access live camera feeds and export video evidence from the UniFi Protect system.
SAFETY FIRST: Always ensure the main equipment is powered down and you have clearance before physically inspecting cables in active machinery areas.
Purpose: To empower field teams to resolve common internet connectivity issues with the Cradlepoint router, minimizing downtime.
Purpose: To correctly decrement inventory and assign costs by checking out parts against a specific job.
Purpose: To correctly increment inventory when new stock arrives.
Purpose: To regularly verify the accuracy of the system inventory against physical stock.