Holley Performance Products Builds a Leaner Carburetor
Air Academy Associates’ SPC XL software
For the first wave of lean Six Sigma projects at Holley Performance Products of Bowling Green, Kentucky, it made sense to direct attention to the cornerstone product in the company’s portfolio: the carburetor. This is the product that launched the company back in 1903 and remains its highest-volume and most recognized product today.
Main-body machining was chosen as an area of focus for this project for a number of reasons: It is the largest component within the carburetor assembly, requires the most machining operations, is the most complex to cast, and serves as the mounting point for many other components. In addition, the manufacturing area was plagued by a number of problems. The process utilized many old, worn-out, manual machines and was labor-intensive. The long changeover time for all of the machines was a huge problem due to the high product mix (approximately 90 part numbers) and small lot sizes (as few as five pieces). The process also generated significant scrap/rework due to variation.
Baseline capability data were gathered for two features on the part. The team chose these features because they were thought to be problem areas. Statistical analysis on the data sets was performed using SPC XL software from Air Academy Associates of Colorado Springs, Colorado.