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| Carl Zeiss Vision in Holford, Birmingham manufactures and distributes lenses for the optical retail industry. It participated in the KITTS scheme via UCE Birmingham, with key objectives to improve operational processes, in particular, to improve quality levels within product manufacturing process. Following the completion of a Degree in Mechanical Engineering at the Technology Innovation Centre in Birmingham, KITTS graduate, Oluseun Osanyingbemi was able to utilise his knowledge and skills by implementing a programme of production quality assessments. Observation, experimental analysis, process auditing, lean and statistical modelling techniques were undertaken with the view to improve operational productivity performance, cut waste, cut costs and improve quality. Oluseun said "Each project/task was different and very challenging, but I was able to transfer and utilise those skills learned from academia to produce tangible results, with substantial impact on the business. The experience I have gained on this programme is a huge reward and I believe it has helped me set out a clear direction in my career path" John Kirk, Head of Business Development at UCE Birmingham Business School felt that the programme was "instrumental in developing a relationship with Carl Zeiss Vision. It enabled the University to understand the needs of the client company and to develop the case for a longer-term relationship. Oluseun developed a strong understanding of the needs and operations of the company. This meant that he gained in confidence and personal effectiveness during his placement with the company". The initial 10-week programme was extended to 44 weeks. Key outcomes for the business were: - Quality improvement audit undertaken on the coating production, with a result of increase in yield of 6 % over period of 5 weeks, this increase was maintained with an overall average increase in yield by 11% over the period of the programme. - Analysis of lens surfacing process with a reduction in production timing of 50%, allowing for a new production tracking system to be installed. - Analysis of product cooling processes and lens density in relation to its curvature undertaken, identifying measurements of lens cooling times to enhance production timing, resulting in a substantial product wastage reduction. - Recommendations for operational restructuring and training requirements were identified and implemented, with a standard operations manual produced for guidance. - A robust Statistical Process Control, SPC database system was developed to monitor production quality parameters, with the ability to give visual representation of quality performance levels. Richard Greenfield, quality Manager at Carl Zeiss Vision considered the programme to be "a huge success, in terms of the analytical work performed by Olu to establish the root cause of quality issues and the implementation of robust corrective actions". |
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