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Functional Devices, Inc., proudly based in the United States, has been designing and manufacturing high-quality electronic devices since 1969. Their mission is to enhance lives in buildings and beyond. They achieve this by delivering reliable, high-performance products for the building automation industry. Their extensive product lineup includes RIB® (Relay in a Box®) relays, current sensors, power supplies, transformers, lighting controls, and more. Every product is rigorously tested—resulting in an industry-leading reliability rate, with fewer than 1 in 16,000 products experiencing a failure in the field. To further ensure customer confidence and peace of mind, they offer an industry-leading 10-year warranty on their products—reinforcing a commitment to quality and longevity. Simply put, when you choose Functional Devices, you're choosing unmatched reliability in every box.

The Challenge:

Functional Devices decided to investigate the plausibility of incorporating Six Sigma methodology within the company to support its strategic objective of operational excellence. The company recognized that Six Sigma training could help identify opportunities for process improvement and promote data-driven decision‑making, potentially resulting in lower production costs, improved product reliability, and stronger customer confidence.

The Solution:  

After piloting Purdue MEP’s Six Sigma Green Belt program with one employee, the leadership of Functional Devices quickly recognized the impact the training could have on cost savings, efficiency, and overall process structure. Since 2024, the company has invested in Six Sigma training for a cross-section of employees, including those in finance, shipping, engineering, quality, and production. In total, Functional Devices now has six certified Green Belts and seven certified Black Belts on staff.

The Results:

Functional Devices has seen impressive results not only from a cost savings perspective but also in overall company culture. By prioritizing Six Sigma methodology as a long-term investment, the company created space for a dedicated team member to oversee all Six Sigma projects and manage the pipeline of future initiatives. Team members are routinely asked to submit potential Six Sigma projects, which are then evaluated for feasibility and, if appropriate, added to the project pipeline.

With the first project completed in late 2024 and several additional projects completed thereafter, Functional Devices has realized annual savings of approximately $250,000 across all completed projects. Highlights from a few projects include:

• Job Changeover Efficiency: This project resulted in a 36% reduction in changeover time.
• Delivery Performance Improvement: On‑time deliveries increased nearly 20% following project completion.
• Production Efficiency: An increase of 26% in efficiency was achieved in one department alone.
• Shipping Capacity Improvement: The number of shipments per employee increased 10% following project implementation.

"One of my biggest takeaways from the Six Sigma program is the clarity the process gives to complicated or seemingly unsolvable issues. The team members across our company are better equipped to not only identify issues that might need improvement, but also have very thoughtful, data-driven conversations with knowledgeable people about the issue. This has helped to enhance our company culture as one of problem-solving and continuous improvement. Having access to this level of training through Purdue MEP has been incredibly valuable to our team."

- David Mackey, Vice President of Manufacturing, Functional Devices