Summer Internship 8/12/2010

Jesse Columbus

Agenda

Projects

• Production Floor Layout

• Curing Oven Standardization

Main Project

• 8 Fiber MPO Improvement

Project: Production floor Layout

Supported fiber production floor plan re-layout.

Improved equipment ergonomics.

Analyzed floor safety audit and conducted a follow up action plan.

Project: Curing Oven Standardization

• Ovens were rebuilt to new rev. of Tooling

• Profiled for correct temperature and ramp time.

• Verified (bi)monthly, profiled semi annually Actual Temp

Oven Set Temp

Main Project: 8 Fiber MPO improvement

Goal: Improve 8 fiber MPO First Pass Yield (FPY) on polishing without negatively impacting CWS inspection at Endface geometry or IL/RL testing

Identify potential root causes

Methodology

DMAIC process

Define: Fish Bone Diagram

Measure: P-Chart on MPO Production Line

Analyze: F-test, T-test, ANOVA, Correlation study

Improve: New Polisher, Lean Replenishment

Control: Continued SPC charting, Visual Floor Signal

Define/ Measure

Fish Bone DiagramIdentified potential root causes

P-chartNumber of conformingMeasured difference in shifts, operators, and polishing equipment

Analysis / Investigation

Hypothesis – repeating step 4 will increase FPY yield and decrease scratches

Defects were decreased Endface geometry was improved The right histogram shows no difference in the mean. ( Type 2 error)

2

543210-1-2

9

8

7

6

5

4

3

2

1

0

543210-1-2

New

Total Defects

Frequency

OldMean 1.2StDev 1.240N 20

New

Mean 1.35StDev 1.424N 20

Old

Histogram of Total DefectsNormal

Panel variable: Process

1.21.00.80.60.40.2

3.0

2.5

2.0

1.5

1.0

0.5

0.0

FPY

Densi

ty

0.8722 0.1399 120.5333 0.1497 12

Mean StDev N

NewOriginal

Process

Histogram of FPYNormal

Improve (six sigma)

New Domallie Polisher

~35*% increase in FPY

~57% reduction in Variation

Cost savings of $24,000 annually 1.00.80.60.40.20.0

2.0

1.5

1.0

0.5

0.0

FPY

De

nsi

ty

0.7303 0.1896 650.5342 0.2694 92

Mean StDev N

NewOld

Polisher

Histogram of FPYNormal

58% average FPY 76% average FPY

FPY %

Improve (lean)

Demand 500 cables per week

Producing 250 cables per week

Value Stream Map

Water Spider pull replenishment. (50 extra cables per week, $500k annually )

Utilized a worker on the MPO line to maximize throughput at the bottleneck produced by the polishing station.

Minimize non-value added activities.

Control

Kurt SPC-Continued SPC charting, Electronically capture data from the MPO polishing station and record the data into p-chart and spreadsheet.

Will send out of control notification

Signal lights for production floor.

Green = operational

Yellow = need a fiber lead to verify work

Red = engineer assistance needed