Abstract

A continuous process improvement (CPI) model guides problem solving activities at EMCO Specialties, Inc. The six major components of the model are: check sheet for data collection; Pareto chart for data evaluation; histogram for analysis of variation; stratification of the problem into smaller elements; flowchart for identification of cost-added and value-added activities; and CEDAC, which analyses root causes. The CEDAC step employs a fishbone diagram and process inputs from machines, methods, materials, people, and the environment. The foundational imperatives of the CPI model are the team approach, continuous improvement, facts, and systematic process. For example, a cross-functional team at an EMCO distribution center used brainstorming and data analysis to identify possible problems with product damage. Their application of the model resulted in two solutions. The first had no effect. The second, which added wraps of stretch film to product packaging, reduced the occurrence of leaning shipping packages by about 95 percent. In three years, this and other CPI initiatives have involved about 30 percent of the EMCO staff and produced cost savings of $750,000.