Download - GRV Heads_pub
T4 Head Scrap/Rework ReductionMike Hutchings/Matt Heath
1MBB Peer Review | 21 Jan 2015
Target date Problem Definition Tree Measurement System Validation
Baseline Process Capability Solution Tree
Post Improvement Process Capability 12/4 Benefits / Business Impact
12/11 Control Plan
12/18
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Commitments from last meeting
Action Date OwnerStatus
Plan to accomplish before next meeting
Action Date OwnerStatus
Determine Post Improvement Process Capability 12/16 Hutchings Complete 12/2
Est. Control Plan & finalize benefits/business impact 12/17 Hutchings/Heath Complete 12/17
Current Phase: DMAICT4 Head Scrap/Rework Reduction
CTQ: Exhaust Face Profile must measure between -.250 and .250 millimeters.
Defect: Any resulting measurement higher than .250, or less than -.250 MM.
Metrics:Baseline: 112,330 DPMOGoal: 11,233 DPMOStretch Goal: 1,123 DPMO
Green Belts : Mike Hutchings
Mentor: Dennis Magerle
Project Approach: DMAIC
Team Members:Matt Heath- PMEAlex Prizzi- QTA
Champion/Sponsor(s): Jeff Reynolds
Benefits: 24,000 cost reduction & increased output by turning a rework only machine into solely production for Strongbacks /Heads.
Schedule:
Problem StatementSince FW 37, 58 Heads in GRV have been scrapped resulting in a loss of $40,136. 130 T4 Heads have been reworked during this time. This prohibits machining & adversely impacts throughput on 1 additional machine for Strongbacks & Heads, since it must solely be used for rework. Additionally, one operator works 2-3 full days/week on rework for T4 heads.
Define problem, prob. Def. tree. ID CTQ’s NLT COB 10/07Measurement system analysis. NLT COB 10/09Create Problem Solution Tree, execute Process Capability & conduct Multi-Vari. 10/13-10/16Screen potential causes & ID relationships, est. operating tolerances 10/23Validate measurement system for Xs 11/02Determine process capability & implement process control 12/16
GRV T4 Heads Scrap/Rework Reduction Current Phase: DMAIC
T4 Cylinder Head Yield
Big Y
GRV Scrap/Rework Rate from FW 37-40 is 2.67 DPU. 188 Scrap/Rework out of 501 Heads.
Quality
Since FW 37, 58 Heads have been scrapped resulting in a loss of $40,136. 130 T4 Heads have been reworked during this time. This prohibits machining on1 additional machine for Strongbacks & Heads, since it must solely be used for rework. Additionally, one operator works 2-3 full days/week on rework for T4 heads.T4 Strongback Yield is being worked in another project.
Problem Definition Tree
GRV DMR’s
T4 Strongback Yield
Exhaust Face Profile All other dimensions
Process capability conducted on all 92 areas of measurement on T4 Head dimensions for 463 Scrap/Rework heads resulted with the Exhaust Face Profile as having the highest PPM. RTV is being worked by Michaele Carney & her team.
ProductVariation
MeasurementVariation
Gage R&R (ANOVA)%Study Var= 7.9%
Exhaust Face ProfileRequired
Existing
.250USL
-.250LSL
Millimeters
Operator toOperator
Supplier to Supplier
Machine to Machine
Part to Part
ProductVariation
MeasurementVariation
Gage R&R (ANOVA)%Study Var= 7.9%
(Multi Vari)
Exhaust Face ProfileRequired
Existing
.250USL
-.250LSL
Millimeters
Time toTime
+.250 MM Rework
0.00 Nominal
Operator toOperator
Supplier to Supplier
Machine to Machine
Part to Part
ProductVariation
MeasurementVariation
Gage R&R (ANOVA)%Study Var= 7.9%
(Multi Vari)
Exhaust Face ProfileRequired
Existing
.250USL
-.250LSL
Millimeters
OP-OP was eliminated due to limited interaction with the operator & process. Once the head is placed in the fixture, the machine takes over and controls the necessary modifications to the exhaust face plane.
Time toTime
USL: .250 MM
LSL: -.250 MM
Pre-Improvement Multi-vari
Rework
Scrap
Operator toOperator
Supplier to Supplier
Machine to Machine
Part to Part
ProductVariation
MeasurementVariation
Gage R&R (ANOVA)%Study Var= 7.9%
(Multi Vari)
Exhaust Face ProfileRequired
Existing
.250USL
-.250LSL
Millimeters
OP-OP was eliminated due to limited interaction with the operator & process. Once the head is placed in the fixture, the machine takes over and controls the necessary modifications to the exhaust face plane.
Time toTime
*Adjusted the g55 z workoffset in program 2100 from -731.498 to -731.648
*Work offset adjustment
*Change G54 X work offset by .100 From -1394.982 to -1394.882
USL: .250 MM
LSL: -.250 MM
Rework
Scrap
Before After
Pre & Post Improvement Multi-variAfter adjustments to the machine based off of the Z & Y dimensions from Long Reports
Stabilized process
Defect Reduction: 112,330->5199
T4 Head Post BenefitsCurrent scrap rate cost of a T4 Head: $682.78YTD T4 Heads machined: 7,767Fully Burdened Labor Rate: $175.66 (overhead & salary)
Pre Improvement:2.9% scrap LSL process capability: .029 x7,767 Heads: 225 Heads scrapped YTDPost Improvement:0% current scrap LSL process capability
$153,791.42 cost reduction in scrap
Pre Improvement:8.2% scrap LSL process capability: 636 Heads Reworked YTD3 Heads reworked per hour .33x $175.66x 225 Reworked Heads= $36,867.52
Post Improvement:.5% current scrap LSL process capability: 38 Heads (P) rework.33x $175.66x 38 (P) Heads rework= $2,251.17 Total: (Improvement Pre-Post) $34,616.35
Scrap Reduction: $153,791.42 +Rework Reduction: $34,616.35 Total cost reduction= $188,407.77Additionally, a machine that was solely used for Head rework has been opened up to machine T4 Strongbacks starting January 2016, which will significantly increase Time on Product.
PRE POST
Control PlanGiven that the post-improvement DPMO results in around 1 defect per week and the process already contains 100% Inspection, the following Control Measures will be implemented:
• Any Head that results in a “Red” Category (greater than +- .250 MM) will result with the next series of Heads from that exact machine being immediately sent to the CMM run to run a Long Report on the Heads (skipping any other Heads that are awaiting CMM). The feedback from the Long Report will tell the Operators if the machine needs to be adjusted based off of the Z & Y dimensions.
• Contact has been initiated with PrimeTech (programmer for the CMM reports) to see if they can alter the program to include the Z & Y dimensions on the Short Report.