manufacturing example2

11

Process Owner: AKGreen Belt: DSSigma Trac ID # : 200601193715

Project Title : Reduction Torn Defect at 1J line

Project Schedule

Definition: 16/02/06 16/02/06Measure: 08/04/06 08/03/06 Analyze: 31/05/06 23/05/06

Improve: 23/06/06 05/07/06

Control: 28/07/06 Validation: 29/09/06

Plan Actual Completion Date Completion Date

2

Project Charter/Statement of Work

CI Statement of WorkDate printed: 5/15/06

Form rev.: 2006_0202a

Project Title:

Location:

Phase Analyze Project # 200601193715

Originator: Jamilah HaronCustomer Quality Focus: NoCreate Date: 2/2/06

Rollout Type:

PROJECT DESCRIPTIONProcess / Product Being Improved:

Project Scope and Boundaries:

Customer Y (s):

Business Y (s):

Problem Statement:

Project Objective / Suspected Root Cause: Primary BBP metric impacted:BBP Product Line:

ESTIMATED SAVINGS (from COPQ)

Est. Hard Savings: 23 Est. Soft Savings:

TEAMProcess Owner: Azhari Kayoon Black Belt: Dewa Shahril MohdNamsah

CI Manager: Mohd Ibrahim Packeer Green Belt:

Type: Black Belt

#N/A#N/A

BB 2006 - JCAI CPPM : Reduction of Door Panel torn defects

Malaysia - KL

1J line process for Door Panels

JCAI Door Panels

Standard

2.00601E+11

Quality

90 pieces of door panels are returned to JCAI due to torn caused by hitting delivery rack

To reduce torn defect 70%

4 - Scrap and Inv Loss Per EQU

Quality

Interiors: Door Panels

Y1= CPPM for door trim (torn defect)

Problem: 90pieces Door trim was send back to JCI due to torn defect. This jeopardizes JCI supplier ranking at Proton

Process: 1J line for door trim

Deliverable: Usable door trim

Objective: Reduce number of defects by 70%

3

Measurement System AnalysisM

easu

re2 (b) Validate measurement System

Appraiser

Perc

ent

21

100

95

90

85

80

75

95.0% CI

Percent

AppraiserPerc

ent

21

100

95

90

85

80

75

95.0% CI

Percent

Date of study: Reported by:Name of product:Misc:

Assessment Agreement

Within Appraisers Appraiser vs Standard

Each Appraiser vs Standard Assessment Agreement Appraiser # Inspected # Matched Percent 95 % CI 1 30 27 90.00 (73.47, 97.89) 2 30 27 90.00 (73.47, 97.89) # Matched: Appraiser's assessment across trials agrees with the known standard.

Within Appraisers Assessment Agreement Appraiser # Inspected # Matched Percent 95 % CI 1 30 27 90.00 (73.47, 97.89) 2 30 29 96.67 (82.78, 99.92) # Matched: Appraiser agrees with him/herself across trials.

4

Cost of Poor Quality D

efi

ne

Number of reject: 246 pieces/3month (Jan 06 – Mar 06)Price for 1 piece of 1J Door Trim = RM 170.68

Cost Of Poor Quality:246 X 170.68 = RM 41987.28/3months

Annualized Cost Of Poor Quality:41987.28 X 4 = RM 167949.12 ~ RM 167949 (USD 44197)

5

Measu

re3 Quantify current performance and

estimate improvement target.

Estimated Improvement Target = 70% Target Sigma = 2.87

Process Sigma Level

Sigma Level (Short-term) = 2.07

Sigma Level (Long Term) = 0.57

From z table :

Baseline PPM (Long-term) = 284,339

Sample

Pro

portion

654321

0.030

0.025

0.020

0.015

0.010

0.005

0.000

_P=0.01921

UCL=0.02574

LCL=0.01267

1

1

Tests performed with unequal sample sizes

P Chart of Return Rejec (Torn)

6

Process FlowM

easu

reSupply raw material

PP sheeting

Forming and trimming

Lamination and trimming

Assembly and Inspection

Storage and delivery

1J product line Process Flow

7

1

PP SHEETING PP sheet no according to size Some area of PVC no laminated/not covered with PP

3 Wrong blade setting/blade broken

2

Not laminate with non woven PVC cannot stick to PP 3 non woven roller not function 2

Thickness not same PVC torn after lamination 3 Roller worn out 1

2 STORAGE WIP Warping Stuck in Oven Conveyor 3Too many layer/some area outside of pallet

3

3 HEATING & FORMING Board too soft Part become soft 3 Heating time too short 2

Board overheat PP become shining/hard 3 Heating tome too long 2

Board offsetSome area of PVC not covered with PP

3PP sheeting not set according to guide

2

Board have sharp edgePVC will easy to torn after lamination process

4 mould design too sharp 3

4 TRIMMING Board have sharp edgePVC will easy to torn after lamination process

4Operator miss to trim sharp edge

3

An

aly

ze4 Identify causes (Xs) of variation and defects.Potential Causes

PotentialItem Process Potential Potential Cause(s)/ Current Current Recommended Responsibility Action Results

# Functions Failure Effect(s) of Mechanism(s) Process Process Actions & Target Actions S O D R.Requirement Mode Failure of Failure Controls Controls Completion Taken e c e P.

Prevention Detection Date v c t N.

R P

N

S E

V

CLA

SS

OC

CU

R

DE

TE

CT

3 HEATING & FORMING Board have sharp edgePVC will easy to torn after lamination process

6 mould design too sharp 6 4 144wk2 March 06 (ME) Modify Mold 6 2 4

48

4 TRIMMING Board have sharp edgePVC will easy to torn after lamination process

6Operator miss to trim sharp edge

5 4 120Wk2 July 06 (CI) New jig 6

22STORAGE AT DELIVERY RACK

Hit rack pillar scratch/torn

6

Door Trim was hit during stacking by workers/hit during transportation

5 3 90 Wrap rack pillars

8

Provide statistical evidence that causes are real.Commit to improvement target for Y.5 Cause Verification

No

Potential Cause

Null Hypothesis

Alternative Hypothesis

Data to verify

Data Type

Verification Method

Results / Conclusion

Cause

1. Molding shape too sharp

Defect ratio no change

Defect ratio lower

Reject data Attribute 1-proportion P-value = 0.00 Yes

2.Delivery rack too hard/sharp edge


Defect ratio lower


3. Rough surface (after trimming)


Defect ratio lower


An

aly

ze

9

Imp

rove

Install solutions and provide statistical evidence that the solutions work.7

Improvement is statistically significant

Test and CI for One Proportions ( = 0.05)

Test of p = 0.0259476 vs p < 0.0259476 95%

Upper ExactSample X N Sample p Bound P-Value

1 13 4016 0.003237 0.005142 0.000

Y = Torn Defect (CPPM) 1J

Action Taken = Mould shape modification

Verified action

10

Imp

rove



Test and CI for One Proportions ( = 0.05)

Test of p = 0.0671463 vs p < 0.0671463 95%

Upper ExactSample X N Sample p Bound P-Value

1 8 642 0.012461 022371.0 0.000


Action Taken = Wrapping Rack Pillars

Verified action

11

Imp

rove




Action Taken = Trimming jig

Verified action

Test and CI for One Proportion Test of p = 0.00324 vs p < 0.00324 95% Upper Exact Sample X N Sample p Bound P-Value 1 0 3726 0.000000 0.000804 0.000

12

Imp

rove

Y= Torn defect at 1J product (CPPM)

Potential Actions

Y Cause Potential Action

Effective -ness

(High/Med/ Low)

Ease to Implement (High/Med/

Low)

Cost to Implement (High/Med/

Low)

Safety Impact

(High/Med /Low)

Torn defect

Molding shape too sharp

Modify mould shape (more curve) High Med Low Med

Delivery rack too hard/sharp edge To wrap all rack High Med Med Low

Rough surface (after trimming) Provide trimming jig High High Med Low

13

Imp

rove

Install solutions and provide statistical evidence that the solutions work.7 Completed Action

Before After

Wrapped rack pillars

14

Imp

rove

Install solutions and provide statistical evidence that the solutions work.7 Completed Action

Before After

Trimming Jig

Use conventional knife

15

Con

trol


Monitoring Process Y

Sample

Pro

port

ion

10987654321

0.030

0.025

0.020

0.015

0.010

0.005

0.000

_P=0.00132

UCL=0.00444

LCL=0

Oct Apr

1

1

1

Tests performed with unequal sample sizes

P Chart of Return reject (torn)

77% reduction

16

Next Activities in My Project

Description of tasks Who Due date

1. To monitor implementation of trimming jig and wrapped rack.

2. To monitor CPPM trend

Azhari End of Aug 06

Dewa End of Aug 06

17

Results Summary

Before After % change

Cost of Poor Quality (Cost Reduction)

Y1 = Torn defect CPPM

Sigma Level (ST) 2.07 3.10

PPM (LT) 284,339 65,522

Before After

284,339ppm (LT) 65,522ppm(LT) 77%

RM 44,197 RM 0 100%

18

Next Steps

Issue List

Issue / Request Suggested Action Owner Est Due date

1 To ensure all rack that use is wrapped properly.

Monitor by production member.Any wrapping damage need to repair prior using.

AK On going

Countermeasure is implementedcontinuously.

To issue new FMEA for process Control.

DS(CI)

3rd wk of Aug 062

Trimming process is using trimming jig

Include in ODS for tool needed. WF ME

3rd wk of Aug 063

manufacturing example2

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