321
Case Problems
• Problem A
– Parts Out of Specification
– Solution: Poor Quality
• Problem B
– Capacity Issue
– Solution: U...
Problem A - Quality
Problem Statement:
Customer has recently found 121 Torsion Bars (T-Bar)
with the Diameter out of speci...
Fishbone Diagram
T-bar
Torsion
Section Is
Too Close
To The
UCL
Process
MeasurementPeople
Operator
Bias
Gage R+R
Too High
S...
Gage Repeatability and Reproducibility
Before Correction
Parts Operator A (mm) Operator B (mm) Range ǀA-Bǀ (mm)
1 0.21858 ...
Gage Repeatability and Reproducibility
After Correction
Parts Operator A Operator B Range ǀA-Bǀ
1 -0.012 -0.013 0.0001
2 -...
Fishbone Diagram
T-bar
Torsion
Section Is
Too Close
To The
UCL
Process
MeasurementPeople
Operator
Bias
Gage R+R
Was Too
Hi...
T-Bar Process Analysis
Pack
110
Q Q Q Q Q
Dept. 30 Dept. 53
Cut
Length
Rough
Grind
Wash Shot
Peen
Paint Serrate Finish
Gri...
Sample Analysis (59 T-Bars)
Bottom Half
Gage Diameter (mm) Occurrences
0.21770 0
0.21775 0
0.21780 0
0.21785 0
0.21790 0
0...
n
x
x
n
i
i
 1
Six Sigma Analysis
where
xi = observation of a quality characteristic (such as time)
n = total number of...
Σ
Six Sigma Analysis
where
xi = observation of a quality characteristic (such as time)
n = total number of observations
xb...
Six Sigma Analysis
UCL 0.21890
xbar 0.21863
LCL 0.21757
0.21750
0.21760
0.21770
0.21780
0.21790
0.21800
0.21810
0.21820
0....
Six Sigma Analysis
0
5
10
15
20
25
Must Move
This Way
)28613.0(x
Left Torsion Right Left Torsion Right
Micro Micro Micro Micro Micro Micro
USL 7.645 USL 5.560 USL 7.645 USL 7.645 USL 5.56...
Problem A Conclusion
• Define
– T-Bar diameter Too Close to UCL
• Measure
– Gage R+R was Poorly Calibrated
• Analyze
– Xba...
Problem B: Capacity Issue
Problem Statement:
Part B orders were eliminated, and an
increase in Part A orders occurred. The...
OP170
Wash
Incoming
From Heat
Treat
OP130
OP140
OD Grind
(12.3 sec/pc)
OP140
OD Grind
(12.3 sec/pc)
OP160
Ball Groove
Grin...
Capacity issue
Document Process
Dept.
1
Dept.
9
Dept.
10
Part A
Part A
Part B
Evaluating the Process
• Cycle Time
• Productivity
• Parts Produced
84 sec/part x 80 parts per cycle 1 hour 52 minutes
Whe...
Products Manufactured v. Product Demand
504
612
108
Products Produced
Product Demand
Short of Demand
Demand – Manufactured...
Recommendations
3) Don’t Change
2) Buy A New Machine
1) Reprogram Idle Machine
Dept.
1
Dept.
9
Dept.
10
Part A
Part A
Part B
Redesigning The Process
1) Manufacture at Full Capacity
2) Produce According...
Problem B Solution
Minimal Costs Associated
Use Idle Machine
and
Produce According To Demand
Inexpensive Change Over Process
Reprogram Machine Replace Part B Pads With Part A Pads
Impact of Labor Costs Using
Two Machines v. Three Machines
Labor Cost/Hour $16.00
Hours/Shift x 7.00
Labor Cost/Shift $112...
Case Problems
• Problem A
– Parts Out of Specification
– Solution: Poor Quality
• Problem B
– Capacity Issue
– Solution: U...
Questions?
of 27

[Name Sponged] Consulting Project

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


Transcripts - [Name Sponged] Consulting Project

  • 1. 321
  • 2. Case Problems • Problem A – Parts Out of Specification – Solution: Poor Quality • Problem B – Capacity Issue – Solution: Utilize Idle Machine 1 9 10
  • 3. Problem A - Quality Problem Statement: Customer has recently found 121 Torsion Bars (T-Bar) with the Diameter out of specification. This issue is a recurring issue and is driving high scrap and sort costs. Torsion UCL – 0.2190 mm LCL – 0.2177 mm
  • 4. Fishbone Diagram T-bar Torsion Section Is Too Close To The UCL Process MeasurementPeople Operator Bias Gage R+R Too High Shot Peen Increases Torsion Size
  • 5. Gage Repeatability and Reproducibility Before Correction Parts Operator A (mm) Operator B (mm) Range ǀA-Bǀ (mm) 1 0.21858 0.21861 0.000030 2 0.21862 0.21864 0.000020 3 0.21864 0.21865 0.000010 4 0.21866 0.21886 0.0002 5 0.21867 0.21883 0.00016 Sum of Range: 0.00042 Gage Error = Sum of Ranges Spec. Limit: 0.0012 (Note: Gage Error equals the sum of ranges only for 5 pc. Study) Gage Capability = Gage Error / Spec. Limit 35.0% Beyond 10% Approval
  • 6. Gage Repeatability and Reproducibility After Correction Parts Operator A Operator B Range ǀA-Bǀ 1 -0.012 -0.013 0.0001 2 -0.002 -0.003 0.0001 3 -0.011 -0.011 0 4 -0.009 -0.009 0 5 -0.003 -0.003 0 Sum of Range: 0.0002 Gage Error = Sum of Ranges Spec. Limit : 0.005 (Note: Gage Error equals the sum of ranges only for 5 pc. Study) Gage Capability = Gage Error / Spec. Limit 4.0% Under 10% Approval
  • 7. Fishbone Diagram T-bar Torsion Section Is Too Close To The UCL Process MeasurementPeople Operator Bias Gage R+R Was Too High Shot Peen May Increase Torsion Size
  • 8. T-Bar Process Analysis Pack 110 Q Q Q Q Q Dept. 30 Dept. 53 Cut Length Rough Grind Wash Shot Peen Paint Serrate Finish Grind Wash 10 40 50 60 70 80 90 100 Quality Check Station Inventory
  • 9. Sample Analysis (59 T-Bars) Bottom Half Gage Diameter (mm) Occurrences 0.21770 0 0.21775 0 0.21780 0 0.21785 0 0.21790 0 0.21795 0 0.21800 0 0.21805 0 0.21810 0 0.21815 0 0.21820 0 0.21825 0 0.21830 0 Top Half Gage Diameter (mm) Occurrences 0.21835 0 0.21840 0 0.21845 0 0.21850 1 0.21855 8 0.21860 18 0.21865 22 0.21870 5 0.21875 1 0.21880 2 0.21885 1 0.21890 1
  • 10. n x x n i i  1 Six Sigma Analysis where xi = observation of a quality characteristic (such as time) n = total number of observations xbar = mean
  • 11. Σ Six Sigma Analysis where xi = observation of a quality characteristic (such as time) n = total number of observations xbar = mean 59 59 i = 10.21863 mm xi =
  • 12. Six Sigma Analysis UCL 0.21890 xbar 0.21863 LCL 0.21757 0.21750 0.21760 0.21770 0.21780 0.21790 0.21800 0.21810 0.21820 0.21830 0.21840 0.21850 0.21860 0.21870 0.21880 0.21890 0.21900 0.21910 1 2 3 4 5 6 7 8 9 1011121314151617181920212223242526272829303132333435363738394041424344454647484950515253545556575859 T-BarGageDiameter(mm) T-Bar Samples T-Bar X Chart Capable process, but shifted to the high end of the specification Target (0.21830)
  • 13. Six Sigma Analysis 0 5 10 15 20 25 Must Move This Way )28613.0(x
  • 14. Left Torsion Right Left Torsion Right Micro Micro Micro Micro Micro Micro USL 7.645 USL 5.560 USL 7.645 USL 7.645 USL 5.560 USL 7.645 LSL 7.595 LSL 5.530 LSL 7.595 LSL 7.595 LSL 5.530 LSL 7.595 Tol. 0.050 Tol. 0.030 Tol. 0.050 Tol. 0.050 Tol. 0.030 Tol. 0.050 Part Left Torsion Right 7.605 5.545 7.604 7.629 5.56 7.628 0.29952 (7.608) 0.21852 (5.550) 0.29968 (7.612) 0.29981 (7.615) 0.21873 (5.556) 0.29999 (7.620) (0.003) (0.005) (0.008) 0.014 0.004 0.008 7.604 5.543 7.603 7.627 5.558 7.625 0.29951 (7.608) 0.21847 (5.549) 0.29956 (7.609) 0.2998 (7.615) 0.21852 (5.550) 0.29963 (7.611) (0.004) (0.006) (0.006) 0.012 0.008 0.014 7.604 5.544 7.604 7.628 5.559 7.626 0.29953 (7.608) 0.21849 (5.550) 0.2996 (7.610) 0.2999 (7.617) 0.21884 (5.559) 0.29994 (7.618) (0.004) (0.006) (0.006) 0.011 0.000 0.008 7.605 5.545 7.604 7.626 5.562 7.626 0.2996 (7.610) 0.21853 (5.551) 0.29966 (7.611) 0.29989 (7.617) 0.21863 (5.553) 0.29989 (7.617) (0.005) (0.006) (0.007) 0.009 0.009 0.009 7.605 5.545 7.605 7.629 5.56 7.626 0.29957 (7.609) 0.21852 (5.550) 0.29965 (7.611) 0.29989 (7.617) 0.2188 (5.558) 0.29991 (7.618) (0.004) (0.005) (0.006) 0.012 0.002 0.008 7.605 5.543 7.604 7.63 5.559 7.628 0.29956 (7.609) 0.2185 (5.550) 0.29969 (7.612) 0.29992 (7.618) 0.218777 (5.557) 0.3 (7.620) (0.004) (0.007) (0.008) 0.012 0.002 0.008 7.605 5.546 7.605 7.629 5.561 7.629 0.29957 (7.609) 0.21854 (5.551) 0.2996 (7.610) 0.29993 (7.618) 0.21877 (5.557) 0.30004 (7.621) (0.004) (0.005) (0.005) 0.011 0.004 0.008 7.603 5.543 7.605 7.63 5.561 7.627 0.29956 (7.609) 0.21857 (5.552) 0.29963 (7.611) 0.29978 (7.614) 0.21871 (5.555) 0.29994 (7.618) (0.006) (0.009) (0.006) 0.016 0.006 0.009 7.603 5.542 7.603 7.628 5.56 7.629 0.2996 (7.610) 0.21853 (5.551) 0.29966 (7.611) 0.29986 (7.616) 0.21888 (5.560) 0.29997 (7.619) (0.007) (0.009) (0.008) 0.012 0.000 0.010 7.603 5.544 7.604 7.6247 5.562 7.626 0.29966 (7.611) 0.21854 (5.551) 0.29963 (7.611) 0.29989 (7.617) 0.21875 (5.556) 0.29984 (7.616) (0.008) (0.007) (0.007) 0.007 0.006 0.010 Average 0.02387 0.0162 0.0229Laser to Micro Max Deviation 0.009 Laser to Micro Max Deviation 0.0160.006 Laser to Micro Average Deviation 0.0217 0.018 0.022 Laser to Micro Average Deviation 0.008 0.027 0.018 0.022 0.025 0.018 0.026 0.025 0.016 0.024 0.024 0.015 0.024 0.022 0.021 0.017 0.022 0.024 0.015 0.021 10 Δ Dia. After Shot Blast 0.0240.0150.024 0.023 0.015 1 2 3 4 5 6 0.022 0.024 0.015 Spec 1 2 3 4 After Grind / Before Shot Blast After Shot Blast Part Laser Laser LaserLaser LaserLaserPart 1 2 3 4 Spec 7 8 9 10 5 6 5 6 7 8 9 10 7 8 9 Process Study – Grind to Shot Peen Difference Between the Sizes Difference Between the Sizes Difference Between the Sizes Difference Between the Sizes Difference Between the Sizes Difference Between the Sizes Difference Between the Sizes Difference Between the Sizes Difference Between the Sizes Difference Between the Sizes Diameter grew by an average of 0.016 mm after the shot peen
  • 15. Problem A Conclusion • Define – T-Bar diameter Too Close to UCL • Measure – Gage R+R was Poorly Calibrated • Analyze – Xbar Chart • Improve – Decrease Rough Grind by 0.016 mm • Control – Keep Gage R+R Under 10%
  • 16. Problem B: Capacity Issue Problem Statement: Part B orders were eliminated, and an increase in Part A orders occurred. The department will be operating inefficiency.
  • 17. OP170 Wash Incoming From Heat Treat OP130 OP140 OD Grind (12.3 sec/pc) OP140 OD Grind (12.3 sec/pc) OP160 Ball Groove Grind (84 sec/pc) OP160 Ball Groove Grind (84 sec/pc) Incoming From Heat Treat OP130 Incoming From Heat Treat OP130 Incoming From Heat Treat OP130 Bottleneck
  • 18. Capacity issue Document Process Dept. 1 Dept. 9 Dept. 10 Part A Part A Part B
  • 19. Evaluating the Process • Cycle Time • Productivity • Parts Produced 84 sec/part x 80 parts per cycle 1 hour 52 minutes Wheel/dress cycle + 04 minutes Total 1 hour 56 minutes Parts/Hour 40.0 Operational Activity (Hours) x 6.3 252 Parts/Shift/Machine Machines/Shift x 2 Total Parts Produced 504 Parts/Shift Productivity 90.0% Shift Time x 7.0 hours Operational Activity 6.3 hours
  • 20. Products Manufactured v. Product Demand 504 612 108 Products Produced Product Demand Short of Demand Demand – Manufactured = Surplus/Deficient of Parts 612 – 504 = 108 17.6%
  • 21. Recommendations 3) Don’t Change 2) Buy A New Machine 1) Reprogram Idle Machine
  • 22. Dept. 1 Dept. 9 Dept. 10 Part A Part A Part B Redesigning The Process 1) Manufacture at Full Capacity 2) Produce According To Demand Dept. 1 Dept. 9 Dept. 10 Part APart A Part A
  • 23. Problem B Solution Minimal Costs Associated Use Idle Machine and Produce According To Demand
  • 24. Inexpensive Change Over Process Reprogram Machine Replace Part B Pads With Part A Pads
  • 25. Impact of Labor Costs Using Two Machines v. Three Machines Labor Cost/Hour $16.00 Hours/Shift x 7.00 Labor Cost/Shift $112.00 Shifts/Year x 365.00 Labor Cost/Year $40,880.00 Deficit/Shift 108 Parts Time Needed for Each Part x 84 Seconds Over Time Needed to Complete Order 1.29 Hours Employee Wage 16.00/Hour Overtime Employee Wage x 2.00 Labor Cost/Day $41.28 Days/Year x 365.00 Over Time Labor Cost/Year $15,067.20 Total Annual Cost $55,947.20
  • 26. Case Problems • Problem A – Parts Out of Specification – Solution: Poor Quality • Problem B – Capacity Issue – Solution: Utilize Idle Machine 1 9 10 Part A Part A Part B
  • 27. Questions?

Related Documents