qcc品管圈课件

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 Temperatureofarea ishigherthanothers 14 CFTanalysisIndepth 14 28 A I C D M water acid 15 Rollcoolinganalysis Scale CaCO3mainly accumulatewithtimegoing thenitcausesthepoorheatconduction 15 28 A I C D M Temperaturedispersion Occurrencestate 16 EvalutionafterpicklingKaizen middle before after Initialfedsheettendtogeneratemoreheat A I C D M 16 28 R 106 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 4Roughpolish 3 7OptimumrollTemp 3 18G466recipeadjustment 4 6Pickling 4 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 Onceayear