cylinder liner boring process improvement case study
DESCRIPTION
Cylinder Liner Boring Process Improvement Case Study. Presented by Dr. Joan Burtner Certified Quality Engineer Associate Professor of Industrial Engineering and Industrial Management. Background. Company is a supplier to an engine manufacturer - PowerPoint PPT PresentationTRANSCRIPT
Cylinder Liner Boring Cylinder Liner Boring Process Improvement Process Improvement
Case Study Case Study
Presented by Dr. Joan BurtnerPresented by Dr. Joan Burtner
Certified Quality Engineer Certified Quality Engineer
Associate Professor ofAssociate Professor of
Industrial Engineering and Industrial Industrial Engineering and Industrial ManagementManagement
ETM 627 Fall 2008ETM 627 Fall 2008 Presenter: Dr. Joan Burtner, Associate Professor of Industrial EngiPresenter: Dr. Joan Burtner, Associate Professor of Industrial Engineeringneering
Slide Slide 22
BackgroundBackground
Company is a supplier to an Company is a supplier to an engine manufacturerengine manufacturer Company’s main product is a Company’s main product is a
cast iron cylinder linercast iron cylinder liner Customer has notified supplier Customer has notified supplier
that it will issue more stringent that it will issue more stringent specificationsspecifications
ETM 627 Fall 2008ETM 627 Fall 2008 Presenter: Dr. Joan Burtner, Associate Professor of Industrial EngiPresenter: Dr. Joan Burtner, Associate Professor of Industrial Engineeringneering
Slide Slide 33
Process Description – Process Description – Flow ChartFlow Chart
ETM 627 Fall 2008ETM 627 Fall 2008 Presenter: Dr. Joan Burtner, Associate Professor of Industrial EngiPresenter: Dr. Joan Burtner, Associate Professor of Industrial Engineeringneering
Slide Slide 44
Problem Definition - Problem Definition - Defects Defects
Application of new specifications to Application of new specifications to historical manufacturing data to predict historical manufacturing data to predict potential defectspotential defects
ETM 627 Fall 2008ETM 627 Fall 2008 Presenter: Dr. Joan Burtner, Associate Professor of Industrial EngiPresenter: Dr. Joan Burtner, Associate Professor of Industrial Engineeringneering
Slide Slide 55
Problem Analysis – Problem Analysis – Potential Root CausesPotential Root Causes
ETM 627 Fall 2008ETM 627 Fall 2008 Presenter: Dr. Joan Burtner, Associate Professor of Industrial EngiPresenter: Dr. Joan Burtner, Associate Professor of Industrial Engineeringneering
Slide Slide 66
Process Data – Initial Process Data – Initial Control ChartsControl Charts
R Chart indicates that the process is out of R Chart indicates that the process is out of controlcontrol
ETM 627 Fall 2008ETM 627 Fall 2008 Presenter: Dr. Joan Burtner, Associate Professor of Industrial EngiPresenter: Dr. Joan Burtner, Associate Professor of Industrial Engineeringneering
Slide Slide 77
Process Improvement Process Improvement – First Stage– First Stage
Investigation showed that a substitute Investigation showed that a substitute operator was working when samples 6, operator was working when samples 6, 16, and 36 were taken16, and 36 were taken
Interviews with line supervisors and Interviews with line supervisors and regular operators uncovered the fact regular operators uncovered the fact that the substitute operator had not that the substitute operator had not been trained on the cylinder boring been trained on the cylinder boring machinemachine
Corrective action: Provide training on Corrective action: Provide training on proper machine operationproper machine operation
ETM 627 Fall 2008ETM 627 Fall 2008 Presenter: Dr. Joan Burtner, Associate Professor of Industrial EngiPresenter: Dr. Joan Burtner, Associate Professor of Industrial Engineeringneering
Slide Slide 88
Process Improvement Process Improvement - Results- Results
R chart indicates that the variability in the R chart indicates that the variability in the process is now in good statistical controlprocess is now in good statistical control
Xbar chart indicates presence of special Xbar chart indicates presence of special causescauses
ETM 627 Fall 2008ETM 627 Fall 2008 Presenter: Dr. Joan Burtner, Associate Professor of Industrial EngiPresenter: Dr. Joan Burtner, Associate Professor of Industrial Engineeringneering
Slide Slide 99
Process Improvement – Process Improvement – Second Stage Second Stage Process Improvement Team (PIT) reviewed Process Improvement Team (PIT) reviewed
the cause-and-effect diagram and decided the cause-and-effect diagram and decided to investigate machine warm-upto investigate machine warm-up
Interpretation: Mean diameter decreases for Interpretation: Mean diameter decreases for first 90 minutes after start-upfirst 90 minutes after start-up
ETM 627 Fall 2008ETM 627 Fall 2008 Presenter: Dr. Joan Burtner, Associate Professor of Industrial EngiPresenter: Dr. Joan Burtner, Associate Professor of Industrial Engineeringneering
Slide Slide 1010
Process Improvement Process Improvement – Additional Results– Additional Results
Process Improvement Team (PIT) Process Improvement Team (PIT) brainstormed optionsbrainstormed options Change operating parameters during Change operating parameters during
warm-upwarm-up Have machine go through accelerated Have machine go through accelerated
warm-up while not producing any partswarm-up while not producing any parts Leave the machine on over the lunch hour Leave the machine on over the lunch hour
and start operation after lunchand start operation after lunch Team chose option 3Team chose option 3
ETM 627 Fall 2008ETM 627 Fall 2008 Presenter: Dr. Joan Burtner, Associate Professor of Industrial EngiPresenter: Dr. Joan Burtner, Associate Professor of Industrial Engineeringneering
Slide Slide 1111
Case StudyCase StudyResolutionResolution
Both R and Xbar charts indicate process is now in controlBoth R and Xbar charts indicate process is now in control
Mean RangeMean Range 7.60 at beginning of case study7.60 at beginning of case study 6.60 at end of case study 6.60 at end of case study
Mean Process Mean changed from 200.250 to 200.005Mean Process Mean changed from 200.250 to 200.005
ETM 627 Fall 2008ETM 627 Fall 2008 Presenter: Dr. Joan Burtner, Associate Professor of Industrial EngiPresenter: Dr. Joan Burtner, Associate Professor of Industrial Engineeringneering
Slide Slide 1212
Acknowledgments/Acknowledgments/Further ReadingFurther Reading
Case study (including figures) adapted Case study (including figures) adapted from Chapter 6 of DeVor, R.E., Chang, T., from Chapter 6 of DeVor, R.E., Chang, T., and Sutherland, J.W. (2007). and Sutherland, J.W. (2007). Statistical Statistical Quality Design and Control: Contemporary Quality Design and Control: Contemporary Concepts and MethodsConcepts and Methods (2nd ed.). Upper (2nd ed.). Upper Saddle River, NJ: Pearson Prentice Hall.Saddle River, NJ: Pearson Prentice Hall.
For additional information on problem-For additional information on problem-solving tools -- Westcott, R.T., Ed. (2006). solving tools -- Westcott, R.T., Ed. (2006). Certified Manager of Quality/Organizational Certified Manager of Quality/Organizational Excellence HandbookExcellence Handbook (3 (3rdrd ed.). Milwaukee: ed.). Milwaukee: ASQ Quality Press.ASQ Quality Press.
ETM 627 Fall 2008ETM 627 Fall 2008 Presenter: Dr. Joan Burtner, Associate Professor of Industrial EngiPresenter: Dr. Joan Burtner, Associate Professor of Industrial Engineeringneering
Slide Slide 1313
Contact InformationContact Information
Email: [email protected]: [email protected] US Mail:US Mail:
Mercer University School of Mercer University School of Engineering Engineering
1400 Coleman Avenue 1400 Coleman Avenue
Macon, GAMacon, GA Phone: (478) 301- 4127Phone: (478) 301- 4127