QCC品管圈PPT课件.pptx

4/28,3.TBRTireManufactureProcess,IL,Sidewall,N-CH,Ply,BeadStiffner,Cushion,TopTread,Belt,Extruding,ILCalendering,BEAD、HSB,Coating&Cutting,IL,sidewall,N.ch,W.ch,Ply,Bead,Cushion,Shaping,Belt,TopTread,Curing,W-CH,TurnUp,A,I,C,D,M,5/28,4-1.BackgroundOfKaizen,A,I,C,D,M,Productionticketcannotbeachievedduetobuildingloss.,WaitingforNo.2/3beltwasmaincauseofproductionloss!,No.1BeltCuttingMachine,4-2.BackgroundOfKaizen,6/28,A,I,C,D,M,1,2,3,4/28,5.DefinitionOfRollAdhesion,A,I,C,D,M,Back,7min,Front,5min,Front,5min,Front,3min,Sheetupthestockedrubber,Reloadandguidesheet,Jointandreapplysheet,Getridofstickyrubber,Depositionofrolladhesion(TS),COPQ,Averageproductionloss815Pcs/Mon(JanandFeb),Lossofconversioncost:300,000RMB/Month,6.ConsequenceOfRollAdhesion,A,I,C,D,M,Thedepositionneedtotalabout20Min.,5/28,RolladhesionurgentlyneedsKaizen!,.,TheIdealState,CurrentOrder:3600Pcs/dayLinespeed:260rpm,MTP:5180Pcs/dayLinespeed:370rpm,220rpmMaximum,TheCurrentState,Setuptarget,8.SetUpTarget,RolladhesionZDLinespeedreach400rpm,A,I,C,D,M,6/28,9-1.Analysis-4M,Operators,Calendermachine,Material,Process,OK,7/28,A,I,C,D,M,OK,NotFoundGap.,ThevoicesofNo.1Beltcuttingmachineoperators:,8/28,9-2.VOCofGenba,HightemperatureofNo.2rollmightcauserolladhesion.,HigherSpeed(81.8%),220rpm,A,I,C,D,M,10.CFTImprovementAnalysis,9/28,A,I,C,D,M,10/28,11-1.AnalysisOfNo.2Roll,Surfacebecometoosmooth,(1)RollSurfaceKaizen,(2)RollTemp.SettingKaizen,Temp.settingcannotbeloweredinfurtherduetomachinecapacity.,A,I,C,D,M,Speedisimprovedto270rpm,Speedisimprovedto250rpm,SPEC:60,270rpm,Confidential,11-2.G466CompoundAdjustment,.EvaluatedItems:,.RecipeReview:,.G.TS2.0.MT1.MT2.Sp.Gr.BP.VD.SLAB,TA39replacetoTE29,(RecipeAdjustment:Costdown:1,000,000RMB/year),Linespeedcanreachto320rpm.,OverallevaluateditemswithinSpec.,*TE29tendstogeneratemoreheatandbesticky.,320rpm,A,I,C,D,M,11/28,12/28,target,80rpm?,“Genbutsu-Genba”onceagain,Roughpolish,RollTemp.condition,Compoundrecipeadjustment,12.SummaryofimplementedKaizen,A,I,C,D,M,13/28,CFTGenbutsu-Genbaonceagain,Ashift:OccurredintheOS,Bshift:OccurredintheOS,Cshift:OccurredintheOS,Dshift:OccurredintheOS,13.Genbutsu-Genbaonceagain,ConfirmofNO.2rolltemperaturedispersion,R=10,ThermographyofNo.2roll,No.2roll,A,I,C,D,M,Temperatureofareaishigherthanothers.,14.CFTanalysisIndepth,14/28,A,I,C,D,M,water,acid,15.Rollcoolinganalysis,Scale(CaCO3mainly)accumulatewithtimegoing,thenitcausesthepoorheatconduction.,15/28,A,I,C,D,M,/28,Temperaturedispersion,Occurrencestate:,16.EvalutionafterpicklingKaizen,middle,before,after,Initialfedsheettendtogeneratemoreheat.,A,I,C,D,M,16/28,R:106,/28,17/28,现行温调管路图,Rolldiameter150mm,Hollowdiameter90mm,-,17.Rollcoolingconstruction,Optimumdesign:Arrayroll,ComparewithBSHZSRroll,ComparewithBSSYCalenderroll,Heatconductingcapacityisinsufficientduetothelargegap,A,I,C,D,M,in,18/28,Redesigndrawing,18.Redesignofroll,Arrayhollowdiameter130mm,-,Heatconductingcapacityofarrayrollisbetter.,out,Rolldiameter150mm,Heatconductgap20mm,-,=,Hollowcoolingpath,Arraycoolingpath,A,I,C,D,M,19/28,A,I,C,D,M,Temp.dispersionevaluation,19.Redesignofroll,Before,After,BeforeKaizen,AfterKaizen,No.3roll,No.2roll,R:61,Afterreplacement,Beforereplacement,20.Improvementsummary,ConfirmofSpeedandadhesion,Linespeedreach420rpmwithoutrolladhesion.,TARGETACHIEVED,20/28,A,I,C,D,M,3/4Roughpolish3/7OptimumrollTemp.3/18G466recipeadjustment,4/6Pickling4/30Rollreplacement,21/28,21.Follow,OperationofA/B/Dshift,Sheetisstocked.,WhyistheCshiftonly?,Stickyareaisrandom,OperationofCshift,Sheetisguideddirectlytotheconveyor.,Slightcasualrolladhesionwasobserved,A,I,C,D,M,22/28,22.ControlandStandardization,Processstandard,Machinestandard,Operationstandard,全员教育,Dept.incharge:Eng.Applyingfrequency:Onceay