coating tech slot dies process troubleshooting six sigma presentation june 2014
DESCRIPTION
Learn about web technology and Six Sigma methodology in process trouble shooting. The presentation explains how to define, measure, analyze, improve and control (or uphold the changes) of your process. The examples included focus on the slot die coating process.TRANSCRIPT
PROCESS TROUBLESHOOTINGWeb Technology and Six Sigma Methodology
Web Processes & Six Sigma
Define Measure Analyze Improve Control
Six Sigma
DMAIC DFSS 3.4 DPMO Doctrine:
Continuous improvement is critical The process can be measured correctly Buy-in from all stakeholders for improvements ($ v
management timeline)
Define
Definitions Where do the defects come from? Goal & Entitlement Discrete plan – Continuous application Team membership
Define
Define v Design Process map Owners v Changers
Measure
Measure the correct things correctly Examples of variables for coating defects
Web (tension, steering and substrate quality) Fluid delivery (pump variation) Coating head (angle of attack) Curing (method stability) Physics (roll diameters)
“What gets measured gets done.”- Tom Peters
Measure
Discrete (widget) v Continuous (web)
Fluid Substrate Coating Head Curing Measurement systems
Coating Variables
Fluid Downweb variation Flow meters Viscosity Mixers Contamination Air Entrapment Temperature control
Coating Variables
Substrate Downweb & Crossweb variation Know what you are getting Surface energy Web cleaners Steering Tension Temperature control Static
Coating Variables
Coating Head Crossweb variation Air entrainment Attack angle (positioning) Roll TIR “Coating window” Edge effects Temperature control
Coating Variables
Curing Stability Temperature control Time requirement v Extent of cure Effect on substrate Method defects (drying, UV, eBeam, etc.)
Coating Variables
Measurement Systems Incoming substrate Coating head Outgoing web Fluid Crossweb Downweb Machine chatter Continuous?
Analyze
Cause-and-effect Statistics “On board” – Team management Roll example Root Cause
"There are three kinds of lies: lies, damned lies and statistics.”- Mark Twain
Improve
DOE Process journal Human element
Improve
Input changes PET cut example
RTY Hard band defect example
Control
Statistical Process Control Continuous improvement
Summary
Web Processes Variables
Fluid Substrate Coating Head Curing Measurement systems
SummarySix Sigma
Define Define v Design
Measure Correct things correctly
Analyze No wasted effort
Improve DOE
Control Continuous improvement
Thank you
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