Spoolshaft Defect Correction
Split the Dictionary:
(Part) No Contrast
Parts were found out of specification randomly.
(Model) No Contrast
Out of spec...
Spool
Blanks
Spool Raw
Machining
Grind/
Stamp
Huffman Grind/
Wash
Grind Slots
and Flats
Feature
Machined
Valve
Assembly
Pr...
Root Cause –
Flat Width Scrap
Δ PΔ M
Measurement Verification
• View Measurement System was found capable of
measuring fla...
Root Cause – Low Effort
Δ P (Defect)Δ M
Not Dimensional Dimensional
Dimensional Defect
• Parts are being scrapped as falli...
Root Cause – Low Effort
Δ P (Defect)Δ M
Not Dimensional Dimensional
Too much Range piece to
piece
Process Mean not
Centere...
Root Cause – Low Effort
Δ P (Defect)Δ M
Not Dimensional Dimensional
Too much Range piece to
piece
Process Mean not Centere...
Concentration Diagram
Min Specification 5.035 Measurement #1 5.144 Min Specification 5.035 Measurement #1 5.081
Max Specif...
Concentration Diagram
Min Specification 5.035 Measurement #1 5.144 Min Specification 5.035 Measurement #1 5.081
Max Specif...
Correlation – Built Into Valves
BOBs
WOWs
ValveEffort
High Effort Spec
Low Effort Spec
Old Low Flat
Width Spec
Current Low...
CORRECTIVE ACTION
Corrective Action
Proposal would be to adjust the Low Flat Width Spec Limit
lower by 20μm. This would al...
• Productivity
• Daily Scrap Cost
• Annual Scrap Cost
Spoolshaft Scrap Improvement: Before
Track the Improvement & Control...
Scrap Cost/Day $149.60
Production Days x 240.00
Scrap Cost/Year $35,904.00
• Productivity
• Daily Scrap Cost
• Annual Scra...
𝑂𝑙𝑑 − 𝑁𝑒𝑤
𝑂𝑙𝑑
= 𝑃𝑒𝑟𝑐𝑒𝑛𝑡 𝐶ℎ𝑎𝑛𝑔𝑒
Scrap Cost/Day $149.60
Production Days x 240.00
Scrap Cost/Year $35,904.00
• Productivity
•...
Questions?
of 15

[Name Sponged] Consulting Project (2)

Published on: Mar 3, 2016
Source: www.slideshare.net


Transcripts - [Name Sponged] Consulting Project (2)

  • 1. Spoolshaft Defect Correction
  • 2. Split the Dictionary: (Part) No Contrast Parts were found out of specification randomly. (Model) No Contrast Out of specification parts were found on both gas and diesel models on both machines in the same locations (Machine) No contrast Both Huffman #11 & #16 both had out of specification parts in the same locations with roughly the same volume of scrap. Location to Location Same Part Part to Part Same Machine Machine to Machine Same Model Same Time Model to Model  (Location) Strong Contrast Out of specification locations were found concentrated to one location radially around the Spoolshaft. Clue Descriptions Strategy Plan
  • 3. Spool Blanks Spool Raw Machining Grind/ Stamp Huffman Grind/ Wash Grind Slots and Flats Feature Machined Valve Assembly Process Flow Diagram
  • 4. Root Cause – Flat Width Scrap Δ PΔ M Measurement Verification • View Measurement System was found capable of measuring flat width within 2% Measurement Position Meas. 1 Meas. 2 Meas. 3 Meas. 4 Meas. 5 Meas. 6 Meas. 7 Meas. 8 Meas. 9 Meas. 10 Max Meas. Min Meas. Range Range x2 Capability Tolerance 1 5.101 5.101 5.101 5.101 5.101 5.101 5.101 5.101 5.101 5.101 5.101 5.101 0.000 0.000 0% 5.135 2 5.082 5.081 5.082 5.082 5.082 5.081 5.081 5.081 5.082 5.082 5.082 5.081 0.001 0.002 2% 5.035 3 5.073 5.072 5.072 5.072 5.072 5.072 5.072 5.072 5.072 5.072 5.073 5.072 0.001 0.002 2% .100mm 4 5.065 5.065 5.065 5.065 5.065 5.065 5.065 5.065 5.065 5.065 5.065 5.065 0.000 0.000 0% 5 5.06 5.06 5.06 5.06 5.06 5.06 5.06 5.06 5.06 5.06 5.06 5.06 0.000 0.000 0% 6 5.081 5.081 5.08 5.081 5.081 5.08 5.08 5.08 5.08 5.08 5.081 5.08 0.001 0.002 2% 7 5.123 5.123 5.123 5.123 5.123 5.123 5.123 5.123 5.123 5.123 5.123 5.123 0.000 0.000 0% 8 5.121 5.121 5.121 5.121 5.121 5.121 5.121 5.121 5.121 5.121 5.121 5.121 0.000 0.000 0% Capability = [(Xmax – Xmin) x 2] / (Print Tolerance) Root Cause Tree
  • 5. Root Cause – Low Effort Δ P (Defect)Δ M Not Dimensional Dimensional Dimensional Defect • Parts are being scrapped as falling above or below a specified tolerance range Root Cause Tree
  • 6. Root Cause – Low Effort Δ P (Defect)Δ M Not Dimensional Dimensional Too much Range piece to piece Process Mean not Centered Dimensional Defect • Of data gathered, it was found that while the mean of the process stays within the tolerance, the range from piece to piece is too large to constrain. Too much Variation piece to piece Root Cause Tree
  • 7. Root Cause – Low Effort Δ P (Defect)Δ M Not Dimensional Dimensional Too much Range piece to piece Process Mean not Centered Too much Variation piece to piece Root Cause Tree
  • 8. Concentration Diagram Min Specification 5.035 Measurement #1 5.144 Min Specification 5.035 Measurement #1 5.081 Max Specification 5.135 Measurement #2 5.124 Max Specification 5.135 Measurement #2 5.064 Spec. Range 0.100 Measurement #3 5.114 Spec. Range 0.100 Measurement #3 5.051 Min Measurement 5.087 Measurement #4 5.087 Min Measurement 5.025 Measurement #4 5.025 Max Measurement 5.144 Measurement #5 5.093 Max Measurement 5.084 Measurement #5 5.034 Range 0.057 Measurement #6 5.112 Range 0.059 Measurement #6 5.064 Average 5.119 Measurement #7 5.135 Average 5.060 Measurement #7 5.079 Measurement #8 5.142 Measurement #8 5.084 Spec. Range on Effort 2.95-3.75 Spec. Range on Effort 2.95-3.75 R.Effort 3.520 R.Effort 3.290 L.Effort 3.430 L.Effort 3.270 Differential 0.090 Differential 0.020 Min Specification 5.035 Measurement #1 5.140 Min Specification 5.035 Measurement #1 5.077 Max Specification 5.135 Measurement #2 5.125 Max Specification 5.135 Measurement #2 5.060 Spec. Range 0.100 Measurement #3 5.107 Spec. Range 0.100 Measurement #3 5.049 Min Measurement 5.091 Measurement #4 5.091 Min Measurement 5.025 Measurement #4 5.025 Max Measurement 5.140 Measurement #5 5.097 Max Measurement 5.077 Measurement #5 5.029 Range 0.049 Measurement #6 5.097 Range 0.052 Measurement #6 5.044 Average 5.115 Measurement #7 5.127 Average 5.053 Measurement #7 5.066 Measurement #8 5.137 Measurement #8 5.074 Spec. Range on Effort 2.95-3.75 Spec. Range on Effort 2.95-3.75 R.Effort 3.460 R.Effort 3.360 L.Effort 3.520 L.Effort 3.470 Differential -0.060 Differential -0.110 Min Specification 5.035 Measurement #1 5.144 Min Specification 5.035 Measurement #1 5.074 Max Specification 5.135 Measurement #2 5.129 Max Specification 5.135 Measurement #2 5.058 Spec. Range 0.100 Measurement #3 5.119 Spec. Range 0.100 Measurement #3 5.046 Min Measurement 5.091 Measurement #4 5.091 Min Measurement 5.029 Measurement #4 5.029 Max Measurement 5.144 Measurement #5 5.102 Max Measurement 5.074 Measurement #5 5.029 Range 0.053 Measurement #6 5.115 Range 0.045 Measurement #6 5.044 Average 5.122 Measurement #7 5.132 Average 5.052 Measurement #7 5.063 Measurement #8 5.141 Measurement #8 5.073 Spec. Range on Effort 2.95-3.75 Spec. Range on Effort 2.95-3.75 R.Effort 3.470 R.Effort 3.300 L.Effort 3.590 L.Effort 3.240 Differential -0.120 Differential 0.060 Huffman #11Huffman #11 Part #8 Huffman #11 Part #9 Huffman #11 Part #10 Part #1 Part #2 Part #3 Huffman #11 Huffman #11 Sample DataANALYSIS A-Start 8 7 6 5 4 3 2 1 • There Are Eight Slots With Flat Widths Ground Around the Spoolshaft. • Starting With A-start, and Measuring Clockwise, the View Measurement System Supplied the Data Where it was Found That All Measurements Near the Top (or A-start) Were High in the Range and All Measurements on the Bottom Were at the Minimum of the Range
  • 9. Concentration Diagram Min Specification 5.035 Measurement #1 5.144 Min Specification 5.035 Measurement #1 5.081 Max Specification 5.135 Measurement #2 5.124 Max Specification 5.135 Measurement #2 5.064 Spec. Range 0.100 Measurement #3 5.114 Spec. Range 0.100 Measurement #3 5.051 Min Measurement 5.087 Measurement #4 5.087 Min Measurement 5.025 Measurement #4 5.025 Max Measurement 5.144 Measurement #5 5.093 Max Measurement 5.084 Measurement #5 5.034 Range 0.057 Measurement #6 5.112 Range 0.059 Measurement #6 5.064 Average 5.119 Measurement #7 5.135 Average 5.060 Measurement #7 5.079 Measurement #8 5.142 Measurement #8 5.084 Spec. Range on Effort 2.95-3.75 Spec. Range on Effort 2.95-3.75 R.Effort 3.520 R.Effort 3.290 L.Effort 3.430 L.Effort 3.270 Differential 0.090 Differential 0.020 Min Specification 5.035 Measurement #1 5.140 Min Specification 5.035 Measurement #1 5.077 Max Specification 5.135 Measurement #2 5.125 Max Specification 5.135 Measurement #2 5.060 Spec. Range 0.100 Measurement #3 5.107 Spec. Range 0.100 Measurement #3 5.049 Min Measurement 5.091 Measurement #4 5.091 Min Measurement 5.025 Measurement #4 5.025 Max Measurement 5.140 Measurement #5 5.097 Max Measurement 5.077 Measurement #5 5.029 Range 0.049 Measurement #6 5.097 Range 0.052 Measurement #6 5.044 Average 5.115 Measurement #7 5.127 Average 5.053 Measurement #7 5.066 Measurement #8 5.137 Measurement #8 5.074 Spec. Range on Effort 2.95-3.75 Spec. Range on Effort 2.95-3.75 R.Effort 3.460 R.Effort 3.360 L.Effort 3.520 L.Effort 3.470 Differential -0.060 Differential -0.110 Min Specification 5.035 Measurement #1 5.144 Min Specification 5.035 Measurement #1 5.074 Max Specification 5.135 Measurement #2 5.129 Max Specification 5.135 Measurement #2 5.058 Spec. Range 0.100 Measurement #3 5.119 Spec. Range 0.100 Measurement #3 5.046 Min Measurement 5.091 Measurement #4 5.091 Min Measurement 5.029 Measurement #4 5.029 Max Measurement 5.144 Measurement #5 5.102 Max Measurement 5.074 Measurement #5 5.029 Range 0.053 Measurement #6 5.115 Range 0.045 Measurement #6 5.044 Average 5.122 Measurement #7 5.132 Average 5.052 Measurement #7 5.063 Measurement #8 5.141 Measurement #8 5.073 Spec. Range on Effort 2.95-3.75 Spec. Range on Effort 2.95-3.75 R.Effort 3.470 R.Effort 3.300 L.Effort 3.590 L.Effort 3.240 Differential -0.120 Differential 0.060 Huffman #11Huffman #11 Part #8 Huffman #11 Part #9 Huffman #11 Part #10 Part #1 Part #2 Part #3 Huffman #11 Huffman #11 Sample Data A-Start 8 7 6 5 4 3 2 1 This data was supplied to the appropriate Manufacturing Engineer who listed many things that could be done to the two Huffmans to improve the range and variability. All of these options were not financially viable to fix this issue when weighted against cost to implement and scrap savings. MID-PROJECT CONCLUSION
  • 10. Correlation – Built Into Valves BOBs WOWs ValveEffort High Effort Spec Low Effort Spec Old Low Flat Width Spec Current Low Flat Width Spec High Flat Width Spec Flat Width ANALYSIS • The Specification of flat widths is to prevent High & Low Effort Valve Assemblies • Recently the grind sheets were updated: • Previous 4.985 - 5.135 • Status Quo 5.035 - 5.135 • We collected BOBs/WOWs that were above and below the current specification limit to correlate flat width to effort. Proposed
  • 11. CORRECTIVE ACTION Corrective Action Proposal would be to adjust the Low Flat Width Spec Limit lower by 20μm. This would allow the Huffman to adjust the mean and produce less scrap at the current machine capability.
  • 12. • Productivity • Daily Scrap Cost • Annual Scrap Cost Spoolshaft Scrap Improvement: Before Track the Improvement & Control: Before Productivity 90.00% Shift Time (Hours) x 8.00 Operational Activity (Hours) 7.20 Cycle Time (Parts/Hour) x 45.00 Parts Made/Day (Gross) 324.00 Parts Made/Day (Gross) 324.00 Scrap Rate x 6.0% Scrap Parts/Day 20.00 Scrap Cost/Part x $7.48 Scrap Cost/Day $149.60 Scrap Cost/Day $149.60 Production Days x 240.00 Scrap Cost/Year $35,904.00
  • 13. Scrap Cost/Day $149.60 Production Days x 240.00 Scrap Cost/Year $35,904.00 • Productivity • Daily Scrap Cost • Annual Scrap Cost • Comparison Spoolshaft Scrap Improvement: Before Track the Improvement & Control: After Productivity 90.00% Shift Time (Hours) x 8.00 Operational Activity (Hours) 7.20 Cycle Time (Parts/Hour) x 45.00 Parts Made/Day (Gross) 324.00 Parts Made/Day (Gross) 324.00 Scrap Rate x 6.0% Scrap Parts/Day 20.00 Scrap Cost/Part x $7.48 Scrap Cost/Day $149.60 Parts Made/Day (Gross) 324.00 Scrap Rate x 1.2% Scrap Parts/Day 4.00 Scrap Cost/Part x $7.48 Scrap Cost/Day $29.92 Scrap Cost/Day $29.92 Production Days x 240.00 Scrap Cost/Year $7,180.80 Scrap Cost/Day $35,904.00 Production Days $ 7,180.80 Scrap Cost/Year $28,723.20 𝑂𝑙𝑑 − 𝑁𝑒𝑤 𝑂𝑙𝑑 = 𝑃𝑒𝑟𝑐𝑒𝑛𝑡 𝐶ℎ𝑎𝑛𝑔𝑒 Track the Improvement & Control: Before
  • 14. 𝑂𝑙𝑑 − 𝑁𝑒𝑤 𝑂𝑙𝑑 = 𝑃𝑒𝑟𝑐𝑒𝑛𝑡 𝐶ℎ𝑎𝑛𝑔𝑒 Scrap Cost/Day $149.60 Production Days x 240.00 Scrap Cost/Year $35,904.00 • Productivity • Daily Scrap Cost • Annual Scrap Cost • Comparison Spoolshaft Scrap Improvement: Before Track the Improvement & Control: After Productivity 90.00% Shift Time (Hours) x 8.00 Operational Activity (Hours) 7.20 Cycle Time (Parts/Hour) x 45.00 Parts Made/Day (Gross) 324.00 Parts Made/Day (Gross) 324.00 Scrap Rate x 6.0% Scrap Parts/Day 20.00 Scrap Cost/Part x $7.48 Scrap Cost/Day $149.60 Parts Made/Day (Gross) 324.00 Scrap Rate x 1.2% Scrap Parts/Day 4.00 Scrap Cost/Part x $7.48 Scrap Cost/Day $29.92 Scrap Cost/Day $29.92 Production Days x 240.00 Scrap Cost/Year $7,180.80 Scrap Cost/Day $35,904.00 Production Days $ 7,180.80 Scrap Cost/Year $28,723.20 $35,904.00 − $7,180.80 $35,904.00 = 𝟖𝟎%
  • 15. Questions?

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