RELY · Quality Containment · Embedded onsite quality teamNO. 15
THIRD-PARTY SORTATION & CONTAINMENT · INJECTION MOLDING
When the hold area became a second production problem, RELY took it over.
The problem was not finding defects. It was clearing held material fast enough without pulling qualified people off production.
- 5.2M+Pieces of held material dispositioned
- 91.1%Returned to usable inventory
- 148MRB events absorbed in 7 months
- 24 hrsMedian MRB closure
What the hold queue was really costing
A highly automated molding operation is efficient right up to the moment a defect requires human judgment. Then the constraint stops being machine capacity and starts being your best people.
HOW IT COMPOUNDED
- 01
DEFECT RUNS
Automation keeps producing.
- 02
HOLD INVENTORY BUILDS
Suspect lots accumulate faster than they can be dispositioned.
- 03
CASH GETS STUCK
Material is neither usable inventory nor confirmed scrap.
- 04
PRODUCTION LOSES PEOPLE
Qualified production resources get pulled into sorting and disposition.
The hold area had quietly become another production department.
WHAT RELY ACTUALLY OWNED
- WORK THE HOLD QUEUESort, inspect, trim, clean, rework and verify suspect material against defined criteria.
- CONTROL THE MATERIALWeighing, box verification, relabeling, repackaging and lot segregation.
- COMPLETE THE DISPOSITIONRelease conforming material, identify scrap by serialized box and close the MRB.
- UPDATE THE SYSTEM LIVECounts, failure mode and disposition entered directly against the work order as the sort runs.
- MAINTAIN TRACEABILITYLot-level records of quantity, failure mode and disposition by MRB.
- ABSORB THE SURGESWhen onsite capacity was not enough, work moved to RELY. One 324,000-piece cavity sort was moved through in a week.
LIVE DISPOSITION. NO SECOND SYSTEM.
Counts, failure mode and disposition were entered directly against the work order while the sort ran. No paper tally waiting to be keyed in two days later.
THE PART YOU DON'T HAVE TO MANAGE
When the onsite lead turned over, we covered it.
RELY's supervisor stepped into the role immediately and built in a full week of overlap at our cost. The customer's team never had to cover the gap.
START HERE
Send us one hold tag.
We'll scope the work and show you what we would take off your team's plate.