Company Name:
BOC Edwards – an international company with a facility in Research Triangle Park
Company Profile:
BOC Edwards is a major supplier of equipment, materials and services for the semiconductor industry. It’s a global industrial gas company employing 43,000 people in more than 50 countries.
Situation:
The semiconductor market fell flat in 2001 and recovery has been slow. This puts pressure on suppliers to offer the best prices and still maintain consistently high quality materials required for the microscopic geometries of the devices.
Project:
BOC Edwards turned to NC State University for Six Sigma Black Belt training for staff throughout the United States. The first Six Sigma project took place at the electronic gas purification and filling facility in Medford, Oregon. To start the Six Sigma project, a team of chemists and process engineers set out to reduce the variation in tested cylinders of WF6 in order to eliminate defects and improve the consistency of the material. To complete its mission, the team opened the Six Sigma toolbox, and applied statistical methods to Medford’s WF6 processes.
Impacts:
Six Sigma methods used to improve tungsten hexafluoride were immediately applied to all of Medford’s gas production processes, resulting in cost reductions and material improvements. This success led to the creation of Six Sigma projects in facilities in Phoenix, Arizona; San Marcus, California; and Johannesburg, South Africa. The Black Belts leading these projects received their training from NC State University. Conservatively estimated, these projects save half a million dollars annually. More Six Sigma projects are being planned for other facilities.
Testimonial:
“We’ve had our affiliation with NCSU for two years now,” said Brian Zievis, Global Technical Manager-Electronic Materials. Zievis was one of BOC Edwards’ first Black Belts trained by NCSU. “Whenever we’ve had a need, these guys (NCSU’s Tim Clapp and Kevin Grayson) are reachable. This relationship has been so valuable. It’s helped us sustain projects and take it where we want it to go. (NCSU dean and Six Sigma leader) Dr. Blan Godfrey’s passion for Six Sigma is contagious. Kevin and Tim really believe in it. Sure, there have been frustrations with some of these projects, but we’ve had a lot of fun, too. We plan to grow (Six Sigma) more.” More BOC Edwards are expected to receive Black Belt training from NCSU in 2003.
January 2003
