TubeLineWastageReduction(6西格玛)

单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,Reduce Wastage of Tube Line,Feb. 6. 2001,The Signature of Quality,1,Project Chart,D,M A I C,2,Project Chart,D,M A I C,Team Members,Flora Yuan Black Belt,Runxia Yang Master Black Balt,George Zhang Champion,Ms. Mo Subcon. Mgr.,Alan Weng Maintenance Sup.,Angel Tang Scheduler.,Wang wenjie Mechanic,Zheng xianhong Electrician,Liu xufeng Foreman.,Wang lan Foreman.,Cui ronghua Foreman.,Wang yiong Foreman.,Support members Karol Bao, Eric,Shen, Hu Yuming,3,D,M A I C,Voice of Customer,Finance,Material wastage high,Filling efficiency low,TQA,Products artwork,not in center,Subcontract,Re-check quality while packing,Packing efficiency low,High Wastage,Low Quality,Export products,rejected,4,SIPOC & Process Map,D,M A I C,Supplier Input Output Customer,Warehouse Raw Material,Warehouse Packaging Material Products Warehouse,Norden, Fryma Machine,Utility Power,Weighing,Mixing,Filling,Packing,Process,TQA,5,Summary of Define Phase,D,M A I C,Identify the voice of customer help project focus on,key points,Clearly understand the project goal and scope are,very important for future progress,Process map and its input and output help team well,know the each process,Team members selection is very important for each,project step,6,Prioritization Matrix Summary,D,M,A I C,.,7,FMEA Summary,D,M,A I C,.,8,Data Collection Plan,Operational Definition and Procedures,Data Collection Plan,What questions do you want to answer?,Data,Data,Method,Weighing,Related conditions,Balance,Sampling Notes,How/where,Mixing,How will you ensure,consistency and stability?,The plan for starting data collection :,D,M,A I C,2.Products artwork mark position vs holder speed,100%,1. Bulk batch quantity vs RO water,Measure,Gauge,100%,Filling,1. Prepare worksheet, chart and gauge for data collection.,2. Training course for operators how to get the data,3. Double check the data,Worksheet, Checklist, Control chart,3. Filling yield vs two ways bulk,fed,Count,Gauge,100%,Filling,9,Gage R&R Study,D,M,A I C,Objective:,Tube center mark eccentric is one of the specification to judge finished goods can be release or reject.,Gage R&R test is to ensure products meet quality spec and we get correct data.,Method:,Three operators measure five samples three times.,Result:,Samples have good reproducibility,Operators have good repeatability,The standard number of distinct categories is 12.,The measurement is good,10,Gage R&R,D,M,A I C,Two-Way ANOVA Table With Interaction,Source DF SS MS P,Unit number 4 17.9058 4.47644 0.00000,operator 2 0.0218 0.01089,0.52574,operator*Unit number 8 0.1249 0.01561,0.00003,Repeatability 30 0.0667 0.00222,Total 44 18.1191,StdDev Study Var %Study Var,Source (SD) (5.15*SD) (%SV),Total Gage R&R 0.081763 0.42108 11.54,Repeatability 0.047140 0.24277 6.65,Reproducibility 0.066805 0.34405 9.43,operator 0.000000 0.00000 0.00,operator*Unit number 0.066805 0.34405 9.43,Part-To-Part 0.704023 3.62572 99.33,Total Variation 0.708755 3.65009 100.00,Number of distinct categories=,12,The standard Number of Distinct Categories should be over 4,The measurement is good,Gage R&R for products mark eccentric,11,Pareto of Opportunities,D,M,A I C,Filling 62.8%,Mixing 29.5%,Weighing 1.4%,Packing 1.0%,Other 3.0%,Most of Material lost in filling and mixing process,12,D,M,A I C,Data(Y) Display,Process Capability of Filling (Wastage 27%),Cpk: -3.36,13,D,M,A I C,Data(Y) Display,Process Capability of Mixing (8% bulk wastage),(,Cpk: 0.08,),14,Summary of Measurement Phase,D,M,A I C,Use Prioritization Matrix to select key data for further study,FMEA analysis show risk in process change,Gage R&R study shows the gauge is products artwork eccentric measure.,Most of material lost in filling and mixing process and those two process capability are quite low.,15,Cause and Effect Analysis,D M,A,I C,People,High,waste,of,Tube line,Material,Seal temperature,Adjust gap,between clamp,Drive system,Tube position,Sensor adjust,Equipment,Electrical adjust,Mechanical transmit,Holder speed,Still fill while without tube,Cooling system,Six tubes always rejected,when the machine start every time,Tube deformation,Untrained operator,New mechanical,Adjust position sensor,or electrical,Set the seal,temperature,Process,Batch quantity,is too small,No special gauge,testing eccentric,Bulk was stored,in small plastic bags,Material remain in vessel &bags,Tube artwork center is,different with the mark,Melt point of tube unstable,Seal unit unstable,Mixing vessel too small,RO water shortage,Water pulled by,vacuum pump,16,Analyze Xs-One - way ANOVA,D M,A,I C,Operators Skill,Analysis of Variance for Filling,Source DF SS MS F,P-Value,Operator 2 243.4 121.7 4.95,0.017,Error 22 541.3 24.6,Total 24 784.6,Individual 95% CIs For Mean,Based on Pooled StDev,Level N Mean StDev -+-+-+-+-,1,9,85.222,5.239 (-*-),2,9,82.667,5.123 (-*-),3,7,77.429,4.315 (-*-),-+-+-+-+-,Pooled StDev = 4.960 75.0 80.0 85.0 90.0,The filling yield was affected by different operators,17,Analyze Xs-Dot Plot,D M,A,I C,Bulk was stored in small plastic bags and fed into the tube machine manually, a lot of bulk remained in bags and bags often broke before being fed into machine.,Transfer the bulk into stainless steel tote from mixing vessel directly, install the membrane pump and electric control system to deliver the bulk to tube machine automatically.,Way of bulk feed into Tube machine,Mean: 25,Mean: 16.8,Filling Wastage was reduced from 25% to 16% after bulk storing totes,18,Analyze Xs-Regression,D M,A,I C,The holder searching mark speed is too fast.,Action: Adjust electric board to reduce the speed,.,Tube Holder Speed,Holder speed reduce from 120 to 60 rpm, the filling wastage reduced 15%,19,Analyze Xs-Box plot,D M,A,I C,Mean: 276.2kg,Mean: 285.4 kg,RO water was short about 10 kg we added in mixing vessel.,Reason: Actual RO water was lower than flow meter setting.,The flow meter suit for 4 tons batch mixing, not suit for 300kg mixing,Action: Weighing RO,water before adding in mixing vessel,RO Water Quantity Improvement,Mixing yield increased 3% after RO water reach Spec.,20,Analyze,D M,A,I C,Viscosity Spec.,50,000,200,000,Viscosity is still within spec after RO water reaching process spec.,Viscosity Comparison by RO water Change,21,Two sample Test -Dot-plot,D M,A,I C,Lot of bulk was remained in mixing vessel after transfer & chemical was remained in weighing bags.,Reason: High viscosity of bulk and chemical.,Action:,Use special tools to scrap the bulk from the wall of vessel.,Use metal bucket instead of plastic bag.,Remained Bulk & Chemical Reduction,285.5,291.1,Mixing yield increased 2 % after using tool scrap the bulk from vessel,22,Summary of Analysis,D M,A,I C,Operators skill are affected filling wastage,When we decide use stainless steel to replace the small plastic bags, bulk wastage reduce 9%.,Reducing the holder searching mark speed, filling yield also reducing,RO water was short than specification in mixing as flow-meter is not suit for small batch of mixing process. Viscosity study shows bulk quality meet spec.,Using special tools to scrap the bulk form vessel can be increase the output.,23,Solution Prioritization Matrix Summary,D M A,II,C,24,FMEA Update,D M A,II,C,25,Cause of Variation and Improve Focus,Products Causes of Variation,Process Fix,1) Operators skills Trained operators,2) Bulk stored in small bags Change to totes,3) Tube holder too fast Adjusted search mark speed,4) Six tube always reject when start Change “O” ring & air cylinder,5) Filler still fill while without tubes Change air valve and fixed,connecting road,6) No spec for tube mark position Spec. has been made,7) RO water shortage Weighing RO water before mixing,8) Bulk remain in vessel Use special tools,Data Driving Process Improvements,Complete,D M A,II,C,26,Before and After Improvements,Improved Process,D M A,II,C,Filling Wastage Reduction,0.6%,27,Before and After Improvements,Improved Process,D M A,II,C,Bulk Wastage Reduction in Mixing Process,3%,Mixing Wastage Reduction,28,Before and After Improvements,Improved Process,D M A,II,C,3.6%,29,Process Fixes and Controls,Causes of Variation,Process Fix,Operators Skills Step Process Training system for operators,and new operators,Tube holder speedSOP Standardization,Seal temperatureSOP Standardization,RO water controlNew Process Weighing,Technique & ProcessBest Practice Planning Changes,Control System,D M A II,C,30,Process Chart/ Check List,1. Scheduler receive order from planning,2. Raw material and RO water weighing.,3. Prepared special tools for scrap the high viscosity bulk & raw material,4.,Operator set up the tube seal temperature according to SOP,5. Operators set up holder speed according to SOP.,6. Operators set up tube machine others in right way,7. Prepared the gage for measure finished goods artwork mark,Production Date:,Yes No N/A,D M A II,C,Line:,31,D M A II,C,Monitoring,After 1.5 month monitoring, the process was well controlled,Cpk: 1.81,32,Lessons Learned / Best Practices,Learnings:,How to improve the process using DMAIIC,Data collection via survey sheets was very useful for real-time data,Checklists help operators to stay focused on task,PE tools help us analyzed data and control process,Best Practices:,Scales must be accurate and have a high degree of repeatability,-When scale counting important to consider individual weight -Need to reflect in procedures,Team work is most important thing on every stage,- Data collection,- Innovation & improvement,-Standardization,D M A II,C,33,Project Description Reduce the wastage of tube line,Customer Benefits Material wastage reduce; Machine efficiency rise; Quality improve,Starting/Ending Sept.12.2000 -Jan 19, 2001,Lessons Learned Using DMAIIC improve the process; Using PE tools analyze data,Key Findings Holder speed on filling process; RO water shortage on mixing process,Improvements Material wastage reduce from,35%,to,3.6%,Controls Mixing Process; Filling new SOP; Check list; Control chart,Savings Savings,1131,M RMB,in 2001 based on forecast,More Information Contact :,Executive Summary,D M A II,C,34,Next PE Project,Reduce adjustment times by PH &Viscosity in RBP system,35,The Signature of Quality,THANKS!,36,