TubeLineWastageReduction.ppt

ReduceWastageofTubeLineFeb 6 2001 ProjectChart DMAIC ProjectChart DMAIC TeamMembers FloraYuanBlackBeltRunxiaYangMasterBlackBaltGeorgeZhangChampionMs MoSubcon Mgr AlanWengMaintenanceSup AngelTangScheduler WangwenjieMechanicZhengxianhongElectricianLiuxufengForeman WanglanForeman CuironghuaForeman WangyiongForeman SupportmembersKarolBao EricShen HuYuming DMAIC VoiceofCustomer Finance Materialwastagehigh Fillingefficiencylow TQA Productsartworknotincenter Subcontract Re checkqualitywhilepacking Packingefficiencylow HighWastageLowQuality Exportproductsrejected SIPOC ProcessMap DMAIC SupplierInputOutputCustomerWarehouseRawMaterialWarehousePackagingMaterialProductsWarehouseNorden FrymaMachineUtilityPower Weighing Mixing Filling Packing Process TQA SummaryofDefinePhase DMAIC IdentifythevoiceofcustomerhelpprojectfocusonkeypointsClearlyunderstandtheprojectgoalandscopeareveryimportantforfutureprogressProcessmapanditsinputandoutputhelpteamwellknowtheeachprocessTeammembersselectionisveryimportantforeachprojectstep PrioritizationMatrixSummary DMAIC FMEASummary DMAIC DataCollectionPlan DMAIC 2 Productsartworkmarkpositionvsholderspeed 100 1 BulkbatchquantityvsROwater Measure Gauge 100 Filling 1 Prepareworksheet chartandgaugefordatacollection 2 Trainingcourseforoperatorshowtogetthedata3 Doublecheckthedata Worksheet Checklist Controlchart 3 Fillingyieldvstwowaysbulkfed Count Gauge 100 Filling GageR RStudy DMAIC Objective Tubecentermarkeccentricisoneofthespecificationtojudgefinishedgoodscanbereleaseorreject GageR Rtestistoensureproductsmeetqualityspecandwegetcorrectdata Method Threeoperatorsmeasurefivesamplesthreetimes Result SampleshavegoodreproducibilityOperatorshavegoodrepeatabilityThestandardnumberofdistinctcategoriesis12 Themeasurementisgood GageR R DMAIC Two WayANOVATableWithInteractionSourceDFSSMSPUnitnumber417 90584 476440 00000operator20 02180 010890 52574operator Unitnumber80 12490 015610 00003Repeatability300 06670 00222Total4418 1191StdDevStudyVar StudyVarSource SD 5 15 SD SV TotalGageR R0 0817630 4210811 54Repeatability0 0471400 242776 65Reproducibility0 0668050 344059 43operator0 0000000 000000 00operator Unitnumber0 0668050 344059 43Part To Part0 7040233 6257299 33TotalVariation0 7087553 65009100 00Numberofdistinctcategories 12 ThestandardNumberofDistinctCategoriesshouldbeover4Themeasurementisgood GageR Rforproductsmarkeccentric ParetoofOpportunities DMAIC Filling62 8 Mixing29 5 Weighing1 4 Packing1 0 Other3 0 MostofMateriallostinfillingandmixingprocess DMAIC Data Y Display ProcessCapabilityofFilling Wastage27 Cpk 3 36 DMAIC Data Y Display ProcessCapabilityofMixing 8 bulkwastage Cpk 0 08 SummaryofMeasurementPhase DMAIC UsePrioritizationMatrixtoselectkeydataforfurtherstudyFMEAanalysisshowriskinprocesschangeGageR Rstudyshowsthegaugeisproductsartworkeccentricmeasure Mostofmateriallostinfillingandmixingprocessandthosetwoprocesscapabilityarequitelow CauseandEffectAnalysis DMAIC People HighwasteofTubeline Material Sealtemperature Adjustgapbetweenclamp Drivesystem Tubeposition Sensoradjust Equipment Electricaladjust Mechanicaltransmit Holderspeed Stillfillwhilewithouttube Coolingsystem Sixtubesalwaysrejected whenthemachinestarteverytime Tubedeformation Untrainedoperator Newmechanical Adjustpositionsensor orelectrical Settheseal temperature Process Batchquantityistoosmall Nospecialgaugetestingeccentric Bulkwasstored insmallplasticbags Materialremaininvessel bags Tubeartworkcenterisdifferentwiththemark Meltpointoftubeunstable Sealunitunstable Mixingvesseltoosmall ROwatershortage Waterpulledbyvacuumpump AnalyzeXs One wayANOVA DMAIC OperatorsSkill AnalysisofVarianceforFillingSourceDFSSMSFP ValueOperator2243 4121 74 950 017Error22541 324 6Total24784 6Individual95 CIsForMeanBasedonPooledStDevLevelNMeanStDev 1985 2225 239 2982 6675 123 3777 4294 315 PooledStDev 4 96075 080 085 090 0 Thefillingyieldwasaffectedbydifferentoperators AnalyzeXs DotPlot DMAIC Bulkwasstoredinsmallplasticbagsandfedintothetubemachinemanually alotofbulkremainedinbagsandbagsoftenbrokebeforebeingfedintomachine Transferthebulkintostainlesssteeltotefrommixingvesseldirectly installthemembranepumpandelectriccontrolsystemtodeliverthebulktotubemachineautomatically WayofbulkfeedintoTubemachine Mean 25 Mean 16 8 FillingWastagewasreducedfrom25 to16 afterbulkstoringtotes AnalyzeXs Regression DMAIC Theholdersearchingmarkspeedistoofast Action Adjustelectricboardtoreducethespeed TubeHolderSpeed Holderspeedreducefrom120to60rpm thefillingwastagereduced15 AnalyzeXs Boxplot DMAIC Mean 276 2kg Mean 285 4kg ROwaterwasshortabout10kgweaddedinmixingvessel Reason ActualROwaterwaslowerthanflowmetersetting Theflowmetersuitfor4tonsbatchmixing notsuitfor300kgmixingAction WeighingROwaterbeforeaddinginmixingvessel ROWaterQuantityImprovement Mixingyieldincreased3 afterROwaterreachSpec Analyze DMAIC ViscositySpec 50 000 200 000 ViscosityisstillwithinspecafterROwaterreachingprocessspec ViscosityComparisonbyROwaterChange TwosampleTest Dot plot DMAIC Lotofbulkwasremainedinmixingvesselaftertransfer chemicalwasremainedinweighingbags Reason Highviscosityofbulkandchemical Action Usespecialtoolstoscrapthebulkfromthewallofvessel Usemetalbucketinsteadofplasticbag RemainedBulk ChemicalReduction 285 5 291 1 Mixingyieldincreased2 afterusingtoolscrapthebulkfromvessel SummaryofAnalysis DMAIC OperatorsskillareaffectedfillingwastageWhenwedecideusestainlesssteeltoreplacethesmallplasticbags bulkwastagereduce9 Reducingtheholdersearchingmarkspeed fillingyieldalsoreducingROwaterwasshortthanspecificationinmixingasflow meterisnotsuitforsmallbatchofmixingprocess Viscositystudyshowsbulkqualitymeetspec Usingspecialtoolstoscrapthebulkformvesselcanbeincreasetheoutput SolutionPrioritizationMatrixSummary DMAIIC FMEAUpdate DMAIIC CauseofVariationandImproveFocus ProductsCausesofVariation ProcessFix 1 OperatorsskillsTrainedoperators2 BulkstoredinsmallbagsChangetototes3 TubeholdertoofastAdjustedsearchmarkspeed4 SixtubealwaysrejectwhenstartChange O ring aircylinder5 FillerstillfillwhilewithouttubesChangeairvalveandfixedconnectingroad6 NospecfortubemarkpositionSpec hasbeenmade7 ROwatershortageWeighingROwaterbeforemixing8 BulkremaininvesselUsespecialtools DataDrivingProcessImprovements DMAIIC BeforeandAfterImprovements ImprovedProcess DMAIIC FillingWastageReduction 0 6 BeforeandAfterImprovements ImprovedProcess DMAIIC BulkWastageReductioninMixingProcess 3 MixingWastageReduction BeforeandAfterImprovements ImprovedProcess DMAIIC 3 6 ProcessFixesandControls CausesofVariation ProcessFix OperatorsSkillsStepProcessTrainingsystemforoperatorsandnewoperatorsTubeholderspeedSOPStandardizationSealtemperatureSOPStandardizationROwatercontrolNewProcessWeighingTechnique ProcessBestPracticePlanningChanges ControlSystem DMAIIC ProcessChart CheckList 1 Schedulerreceiveorderfromplanning2 RawmaterialandROwaterweighing 3 Preparedspecialtoolsforscrapthehighviscositybulk rawmaterial4 OperatorsetupthetubesealtemperatureaccordingtoSOP5 OperatorssetupholderspeedaccordingtoSOP 6 Operatorssetuptubemachineothersinrightway7 Preparedthegageformeasurefinishedgoodsartworkmark ProductionDate YesNoN A DMAIIC Line DMAIIC Monitoring After1 5monthmonitoring theprocesswaswellcontrolled Cpk 1 81 LessonsLearned BestPractices Learnings HowtoimprovetheprocessusingDMAIICDatacollectionviasurveysheetswasveryusefulforreal timedataChecklistshelpoperatorstostayfocusedontaskPEtoolshelpusanalyzedda