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T4 Head Scrap/Rework Reduction Mike Hutchings/Matt Heath 1 MBB 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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Page 1: 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

√√√√√√√

Page 2: GRV Heads_pub

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

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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

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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.

Page 5: GRV Heads_pub

ProductVariation

MeasurementVariation

Gage R&R (ANOVA)%Study Var= 7.9%

Exhaust Face ProfileRequired

Existing

.250USL

-.250LSL

Millimeters

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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

Page 7: GRV Heads_pub

+.250 MM Rework

0.00 Nominal

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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

Page 9: GRV Heads_pub

USL: .250 MM

LSL: -.250 MM

Page 10: GRV Heads_pub

Pre-Improvement Multi-vari

Rework

Scrap

Page 11: GRV Heads_pub

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

Page 12: GRV Heads_pub

*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

Page 13: GRV Heads_pub

Rework

Scrap

Before After

Pre & Post Improvement Multi-variAfter adjustments to the machine based off of the Z & Y dimensions from Long Reports

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Stabilized process

Defect Reduction: 112,330->5199

Page 15: GRV Heads_pub

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

Page 16: GRV Heads_pub

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.