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Quicklychangethermocouple Issue Theme ReasonForSelection Thermocoupleistoolongthenitneedbebentandenlaced Oncethermocoupleisdamaged alsoneedtoexpendmanytimetochangeit Thethermocouple connecter lead thermocouple function measureandmonitortemperatureofmolddie UnderstandingCurrentSituation CI Step 2 Ittakemanytimeforchangingonebadthermocouple CI Step 2 UnderstandingCurrentSituation whenathermocoupleisbadandneedchange sometechniciandon ttakeoutbadthermocouple onlyaddaanewthermocoupletoreplacebad effectitsappearanceand5S CI Step 3 GoalSetting Plan Goal ReducethetimeforchangingabadthermocoupleFromavg 20mintoavg 5minImprovementmold5SDuedate ww28 2007 CI Step 4 De runnerdegaterunner PickupL Fonloader Moldprocess PutL Fintomolddie OutlineofEquipment Process Temperaturecheck Sizetemperature Heatoff Heaton Flowoftemperaturecontrollingsystem Molddietemperature180 Y N Heatcontroller Molding Cure TP FE CI Step 5 ClarificationofPhenomenon Problem Checkandconformthermocouple Changeortakedownbadthermocouple Findtemperatureabnormal DuringPMwork hydraulic PM MolddiePM Verifythethermocouples Disentanglecircuit Takedownbadthermocouple Setnewthermocouple Enlacedcircuit Tracking Changeprocess Wastemoretimeandthethermocouplescouldbedamagedeasy CI Step 6 Timeanalysis Level1 RootCauseAnalysis CI Step 7 Countermeasures A B C Original A B C improvement connecter Addedconnecter Theorysupport MeanConductorLaw EABC EAB Accordingtomeanconductorlaw accuracyofthermocouplehavetodowithtemperatureofthermocoupleheadonly CI Step 7 Action Modifythermocouplestructurefromholistictosubsection reducelengthofcircuitfrom1500mmto1000mm Countermeasures Aftermodify Beforemodify thermocouple 1400 1500mm 800mm connecter 200mm thermocouple CI Step 7 Countermeasures OverallnewthermocouplearecalibratedandpassedbyQA CI Step 7 Tracking Upperlimit Lowerlimit CollectMP10allchase stemperatureon23and24 Apr Countermeasures CI Step 7 Countermeasures BeforeVsAfter Disentanglecircuit Takebadthermocouple Setnewthermocouple Enlacedcircuit Loosemiddleconnecter Takebadthermocouplehead Setnewthermocouplehead Tracking Tracking Averagesavetime15minuteperthermocoupletodisentangleandenlacedcircuit CI Step 8 EffectivenessVerification New Original TrackMP10status decreasechangetimefromaverage20mimutesto5minutes improvemoldmachine5s achieveteam sgoal FinancialAnalysis ValidateFinancialBenefits Throughimprovethermocouple reducethechangingdowntimeforalarm aboutheatercontroller fromaverage20minutesto5minutes Reducedowntime1 line 20 81 5 12month 1 month 183 72minutes2 Throughimprovethermocouple reducethechangingtimeformaintenance aboutheatercontroller fromaverage30minutesto10minutes Reducedowntime2 line 30 10 2 40minutesSo addadditionaloutput suchasMP10 Additionaloutput UPH time1 time2 60 61 44 183 72 40 60 229 09 k 3 Thecostchangingaboutthethermocoupleislow 4 ThetotalcostsavingforMP10 Totalcostsaving line 229 09 7 5 80 1000 1 37k5 Thetotalcostsavingforallmanualmoldmachine Totalcostsaving 25 1 37 34 36k CI Step 8 CI Step 9 PreventRecurrenceandstandardization 800mm connecter 200mm CI Step 9 PreventRecurrenceandstandardization DiscusswithMFG vendor wedecidetousethisnewtypethermocouplestepbystep Standardizati
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