美国500强公司6 Sigma 项目精典案例

ProjectName:setupreductionimprovementforTempusautolineValuecenter:XXXXshenzhenChampion:MBB:XXXXXX.GutieBB:XXXXX.IiAsTempusproductsisthekeyproductsseriesforourcompany,tempusauto-lineproductssalesis30%ofourwholesales.TheoperationmanagerproposedtocarryonSetupreductionprojectonTempusautomaticline.andthenwebuildstrongimprovementteam.Westartedbycollectingcurrentsetup&changeovertimeforTempusM2machine,andwecollectedhistoricdataasbaseline.finishedfinancialsavingunderfiancéapproval.werecordM2Machinesetupwholeprocessbydigitalvideo.documentationalleventsforallsetupprocess.separationexternaltimeandinternaltime.convertinternaltimetoexternaltimebyteambrainstormingandwatchingvideo..byeliminateadjustmentduringsetup.Finally,wereviewprocessCPK,again,anddocumentallimprovementresult.Issuenewsetup&changeoverinstruction.Executive

SummaryWhatisthebackgroundofthisproject?1.Tempusoutputisabout30%ofwholecompanysaleachievement.2.thecustomer’sdemandisincreasing.3.Asfollowingrequirement,butourtempusmachinesetuptimeabout3.5h,limits.Tempusproductioncapacityandquickresponsetocustomer.autolinemanufacturingprocessscraprateis0.98%4.Therequirementofgeneraltargetofcompany(efficiencyimprovement,scrapreduction)Whatmaytheprojectbefocusedon?1.increaseassemblyefficiency(setupreduction)2.ScrapreductioninthemanufacturingprocessWhataretheriskandchallenges?Teammembertimelimitation.Processengineerandblackbeltarenewtothecompany,notmuchofexperienceProductionlineburdenisheavy.Butprojectwilltakeupsomeproductiontime.LackenoughsupportofteammemberProjectgoal&objectivesProcessimprovementsinmachinesM2,M1,M3andF2Reducesetuptimeform3.5hoursto2hoursScrapratereduction:from0.98%to0.78%ImprovetechnicianSMEDknowledge,andproductionlinespareparts&toolmanagement5S.ProjectTimeframeStart:2006-June17thEnd:2006-sep6th-DefineProblemStatement/问题描述Teammember/团队成员-Define详见：Projectschedule

ThescrapratebaselineforTempusautolineIdentifyBaseline0.2%reductionDefine

thechangeover&setuptimebaselineforTempusautomachineM21.5HOURSPDFForm/完成PDF表-DefineProcessMapping/流程分析Theautomaticlinehas4workstationsPreparingmaterialFinishedgoodsKeyprocess-MeasurePackingonpackingM/C

Machinesetup/changeovertakes3.5hoursAbout2timechangeoveraredonein1dayJune1~june6scrapcondition.InsertioncontactsonassembleM/CPrintmarkonprinterscrapSetup&changeoverElectricaltestNGOKTempusautomaticassemblemachineInsulationscratchismosthighpercentChangeoverandsetupforthe3units1.Inallldifferenttypedefectsandscrap.2.Weneedspend3.5hourstosetupthe4assemblyunitstopreparethenewproductionorder.Currentsetupdocumentationworksheet-MeasureAccordingwithcurrentsetupcondition,wevideorecordedthesetupprocessandfinishedthedocumentationworksheet.MSA/量测系统的分析-MeasureGageR&RStudy-ANOVAMethodGagename:contactsheightmeasuretoolsDateofstudy:June-10-2006Reportedby:ping.liTolerance:0.01mm%ContributionSourceVarComp(ofVarComp)TotalGageR&R0.00002676.44Repeatability0.00002175.23Reproducibility0.00000501.21operator0.00000090.21operator*sample0.00000411.00Part-To-Part0.000387793.56TotalVariation0.0004143100.00Study?Var%Study?Var%ToleranceSourceStdDev(SD)(6?*?SD)(%SV)(SV/Toler)TotalGageR&R0.00516400.03098425.3715.49Repeatability0.00465470.02792822.8713.96Reproducibility0.00223610.01341610.996.71operator0.00092960.0055784.572.79operator*sample0.00203370.0122029.996.10Part-To-Part0.01968890.11813496.7359.07TotalVariation0.02035490.122129100.0061.06NumberofDistinctCategories=5

FromtheGageR&Rvaluewecanfindmeasuresystemisingoodcondition,weneednotimproveit!Contactheightmeasuregage:ThedimensionLisverycriticaldimensionforcustomer,sowedidGaugeR&Rforcontactheightmeasurementgage.currentCp,Cpk/controlchartCurrentCPkofcontactheightM2:Customerspec.:6.5+/-0.1mmCPK=1.43CP=1.71PPM=3096过程能力分析可以量测KPOV，也可以量测KPIV，记录要保存，可以作为改善后的一个重要的比照值-MeasureForTempusMaleconnector,thecontactheightisakeycontrolparameter.FromCPk,andcpdata,wecanseeinsertioncontactsprocessshowgoodcapacity.Thecurrentassemblyprocesscapacityforcontactsheight.Refinethecriticalinput/筛选因素-Analyze

Effect::finishedgoodsinsulationscratchMachineMethodsMeasurementsManpowerAssembleMachineNotenoughstaffingduringpeaktimesNotfollowworkinstructionContactholderproblemInsertionparameterToomany“jumps”

feedingdeviceIncompleteTrainingoncommoncomplaintsUnfamiliaritywithproceduresMarketingmetricscounterproductiveNotificationofabsenceForvacationnotificationManagementPoliciesMaterialMotherNaturetemperatureContactchamferInsulationholeOperationinstructionnotdetailedPusherPartwarityhumidityScrapontestunitScraponpackingunitRefinethecriticalinput/筛选因素-Analyze

Fromparetochartwecanseecontactschamferhasgreateffecttoproductquality(insulationscratch).InsulationscratchproblemC&EmatrixSolutionApproach/拟订对策方案-Analyze

Planned2006ActionStep/KaizenEventsOwnerAssistDatesJJAImprove

4.setupreductionimprovement

4.1teambrainstormingforidentifytheinternaltimeandexternaltimeping.liteam6/20/2006x

4.2separatesetuptimeasintenaltime&extenaltimeping.liteam6/20/2006x

4.3.ConvertInternaltoExternaleventsping.liteam6/25/2006x

4.4Streamlineinternalevents(Simplify,Reduce,Eliminate)ping.liteam6/28/2006x

4.5Eliminateadjustmentsinternaltothesetupping.liteam6/282006x

5.5Sandworkingtoolsmanagementimprovement

5,1thetoolsandtoolboxpurchasingcoshingfox;ping6/23/2006x

5.2definespecifiedthesetupconsequeceandmovingtrackingcoshingfox;ping6/24/2006x

5.3improvespearepartsmanagementcoshingfox;ping6/25/2006x

5.4traningimprovedtechnologyandfixture/process,foralltchnician&setter.ping.li

6/27/2006x

6.theinslationscrapimprovement

6.1NPDissuetheupdateddrawingbill.liu

6/20/2006x

6.2stampingdepartmentchangedieaccordingengineeringdrawinghanse

6/30/2006x

6.3qulifytheupdateddieandmakesamples.;doFAIbill.liufox;7/2/2006

x

6.4trackinslationscrapproblemifitisok,thenmassiveporductioncoshing

7/5/2006

x

FinalsolutionDesign/最终对策方案-ImproveStep1.DocumentationandSeparationOriginalSetupSTEP1:Document&Separate3:292:49EXTERNALINTERNALTIME-Improve2.ConvertInternaltoExternalevents.FinalsolutionDesign/最终对策方案3:292:492:37EXTERNALINTERNALOriginalSetupDocument&SeparateConvertinternaltoexternalTIME3:29StatusofPlan/对策执行进度表-Improve2:012:492:37OriginalSetupDocument&SeparateConvertinternaltoexternalStreamEXTERNALINTERNALSolutionApproach/对策验证-ImproveapplicatorAss’yVibbowlTesterprogrammeContactsstoreprinterPackingM/CContactsdereelM/cInspectionSparebowlContactsfeedingdevicesX23DmeasurerPinheightmeasure,visualinspectiontoolsToolboxPackingsetuppannelToolboxThemovingtrackbeforeimprovementThemovingtrackafterimprovementBeforeimprovement:1.Onetimesetuptechnicianwillmoveabout540steps(average).2.Therelatedsparepartsandtoolswerelocatedinadifferentplace.Techniciansneedtofetchthetoolseveraltimes.3.Productionlinedonohaveastandardsetup&changeoverinstruction.Differenttechnicianusedifferentmethod.Ass’yVibbowlTesterprogrammeContactsstoreprinterPackingM/CContactsdereelM/cInspectionSparebowlContactsfeedingdevicesX23DmeasurerPinheightmeasure,visualinspectiontoolsapplicatorToolboxPackingsetuppannelToolboxAfterimprovement:1.Foronetimesetuptechnicianwillmoveabout200steps(average).2.Therelatedsparepartsandtoolwerelocateddifferentplace.Techniciansneedtofetchthetoolseveraltimes.3.Wedrawalltechnician'sgoodexperiencestodevelopastandardsetup&changeoverinstruction.Everyonemustobeytheinstruction.SolutionApproach/对策验证-ImproveBeforeimprovement:1.Technicianseldomrealizethatexternaltimeandinternaltime,almostallthejobsweredoneduringdowncondition.2.Therelatedsparepartsandtoolwerelocateddifferentplace.techniciansneedfetchthetoolforseveraltimes.3.Productionlinenostandardsetup&changeoverinstruction.Differenttechnicianusedifferentsetupconsequence.4.The5SconditionatMaterialareaisverypoor.Operatorfindingmaterialneedalottimetime.5.QAFAIforeveryshiftisveryslow,machineneedstoptowaitingforresult.6.Theinformationtransfterringduringshiftchangeisnotperfect.afterimprovement:1.Aftertheprojectalltechniciansconditionhadtheconceptionofexternaltimeandexternaltime,theydorelatedpreparejobsinexternaltime..2.Forthepublictools,wesetspecifiedtoolbox.Everyshifthastheirowntoolbox,duringchange&setuptheyneednotfetchtoolforseveraltimes.3.Processengineercreatedthestandardmachinesetup&changeoverinstructionforM2,F2,M3,allofthemobeytheinstructions.4.The5SconditionatMaterialareaisimproved.itmakethemfindrelatedmaterialeasily.5.QAdepartneedfinishstartingmachineFAIin5minutes,6.Coshingcreatedperfectpolicyforshiftschangeandrelatedinformationtransfterring.Allthetechnicianmustfillshiftchangelog.SolutionApproach/对策验证-ImproveThemovingtrackbeforeimprovementThemovingtrackafterimprovementUnchamperedcontactAchamferedcontactBChamfer,noinsulationscratch

noChamfer,insulationscratch

1.Therearesomeinsulationdamage.2.Weneed2Operatorwithtoothbrushtoremovetheinsulation.1.Therearenoinsulationdamage.WeneednotoperatortoremovetheinsulationdamageproblemSolutionApproach/对策验证-ImproveimproveCPkofcontactheightM2:Customerspec.:6.5+/-0.1mmCPK=4.92CP=5.04PPM=0.40Sigma=6.44AfterimprovementWereviewthecontactheightagain.A.直接人工本钱削减〔OperatingProfit)onconditionthat;1technician’ssalary2000RMB/month*;2timeschangeover/24hours;工程预计收益=(3.5-2)*2*21*2*1.448=$3.75k/yearB.报废品本钱消减〔OperatingProfit)formJantoAprilTempusproductsscrap:averagerate0.98%14323.63USD;reduceto0.78%工程预计收益=$9k/yearC.Additionalrevenue=$31.2k/yearannualtimesaving:(3.5-2)*2*21*12=756hours;themincapacityofmachine:140pcs(25.6s/pcs)140pcs(25.6s/pcs)unitsprice=0.785usd(121687-232-000VR)15%*425250*0.785USD/pcs=37.5kUSD37.5*(24-4)/24=31.2kusd工程预计年硬性总收益=3.75k/year工程预计年软性总收益=$40.2k/year工程预计年总收益=$43.75k/ye