QCC品管圈ppt演示课件

Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 4/28 3.TBR Tire Manufacture Process IL Sidewall N-CH Ply Bead Stiffner CushionTop Tread Belt Extruding IL Calendering BEAD、HSB Coating & Cutting ILsidewall N.chW.ch Ply Bead Cushion Shaping Belt Top Tread Curing W-CH Turn Up AICDM . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 5/28 4-1.Background Of Kaizen AICDM Production ticket can not be achieved due to building loss. Waiting for No.2/3 belt was main cause of production loss! . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 No.1 Belt Cutting Machine 4-2.Background Of Kaizen 6/28 AICDM . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 1 2 3 4/28 5.Definition Of Roll Adhesion AICDM . Back 7min Front 5min Front 5min Front 3min Sheet up the stocked rubber Reload and guide sheetJoint and reapply sheet Get rid of sticky rubber Deposition of roll adhesion(TS) COPQ Average production loss 815Pcs/Mon ( Jan and Feb) Loss of conversion cost: 300,000RMB/Month 6. Consequence Of Roll Adhesion AICDM The deposition need total about 20Min. 5/28 Roll adhesion urgently needs Kaizen! . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 The Ideal State Current Order : 3600Pcs/day Line speed : 260rpm MTP : 5180Pcs/day Line speed : 370rpm 220rpm Maximum The Current State Huge Gap Set up target 8.Set Up Target Roll adhesion ZD Line speed reach 400rpm AICDM 6/28 . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 9-1. Analysis-4M OperatorsCalender machine MaterialProcess OK 7/28 AICDM ItemResultSpecificationJudgement Cooling capacity Temp. conform to setting Conforming to setting OK The cooling pipe jam Flowing freelyFlowing freelyOK Rolls gear ratio 1 : 1 : 11 : 1 : 1OK OK Not Found Gap. . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 The voices of No.1 Belt cutting machine operators: 8/28 9-2.VOC of Genba High temperature of No.2 roll might cause roll adhesion. Higher Speed (81.8%) 220rpm AICDM . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 10.CFT Improvement Analysis 9/28 AICDM . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 10/28 11-1.Analysis Of No.2 Roll Surface become too smooth (1) Roll Surface Kaizen(2) Roll Temp. Setting Kaizen Temp. setting can not be lowered in further due to machine capacity. AICDM Speed is improved to 270rpmSpeed is improved to 250rpm SPEC:60 270rpm . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 Confidential 11-2.G466 Compound Adjustment . Evaluated Items: .Recipe Review: .G .TS2.0 .MT1 .MT2 .Sp.Gr .BP .VD .SLAB TA39 replace to TE29 (Recipe Adjustment: Cost down:1,000,000RMB/year) Line speed can reach to 320rpm. Over all evaluated items within Spec. *TE29 tends to generate more heat and be sticky . 320rpm AICDM 11/28 . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 12/28 target 80rpm? “Genbutsu-Genba” once again Rough polishRoll Temp.condition Compound recipe adjustment 12. Summary of implemented Kaizen AICDM . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 13/28 CFT Genbutsu-Genba once again A shift: Occurred in the OS B shift: Occurred in the OS C shift: Occurred in the OS D shift: Occurred in the OS 13.Genbutsu-Genba once again Confirm of NO.2 roll temperature dispersion R=10 Thermography of No.2 roll No.2 rollNo.2 roll AICDM Temperature of area is higher than others. . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 14.CFT analysis In depth 14/28 AICDM . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 water H2OH2O H2O H2O acid acidacid acid acid 15.Roll cooling analysis Scale(CaCO3 mainly) accumulate with time going, then it causes the poor heat conduction. 2+CaCO3 + 2H = Ca + H2O +CO2+ 15/28 现行温调管路图 No.2 roll mechanical drawing AICDM /28 . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 Temperature dispersionOccurrence state: 16.Evalution after pickling Kaizen middle before after Initial fed sheet tend to generate more heat. AICDM 16/28 R: 10 6 /28 . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 17/28 现行温调管路图 Roll diameter 150mm Hollow diameter 90mm - 17.Roll cooling construction in out 60mm Optimum design: Array roll Compare with BSHZ SR roll Compare with BSSY Calender roll 60mm Heat conducting capacity is insufficient due to the large gap AICDM . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 20mm in 18/28 Redesign drawing 18.Redesign of roll Array hollow diameter 130mm - Heat conducting capacity of array roll is better. out Roll diameter 150mm Heat conduct gap 20mm -= in out Hollow cooling path Array cooling path i n out 20mm 60mm AICDM . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 19/28 AICDM Temp.dispersion evaluation 19.Redesign of roll Before After Before Kaizen After Kaizen No.3 roll No.2 roll R: 6 1 After replacement Before replacement . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 20.Improvement summary Confirm of Speed and adhesion Line speed reach 420rpm without roll adhesion. TARGET ACHIEVED 20/28 AICDM . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 3/4 Rough polish 3/7 Optimum roll Temp. 3/18 G466 recipe adjustment 4/6 Pickling 4/30 Roll replacement 21/28 21.Follow Operation of A/B/D shift Sheet is stocked. Why is the C shift only? Sticky area is random Operation of C shift Sheet is guided directly to the conveyor. Slight casual roll adhesion was observed AICDM . Copyright 2011 Bridgestone Corporation | Sep.12. 201 4 22/28 22.Control and Standardization Have Contacted BSJ-TC Process standard Machine standa