6西格玛黑带项目案例

Define Section 1 Climate Controls OEM Products Group Reduce Returns of 24245 SIX SIGMA BLACK BELT PROJECT CANDIDATE: PETER WRIGHT CHAMPION: KEVIN KIDDER START FEBUARY 18, 2002 ESTIMATED COMPLETION JULY 15, 2002 Define Section 2 Climate Controls OEM Products Group Define Project DMAIC REVIEW DEFINE MEASURE ANALYZE IMPROVE CONTROL Develop charter Map the process Understand the voice of the customer Measure Section 3 Climate Controls OEM Products Group SIPOC Suppliers – Inputs – Process – Outputs - Customers Inputs 24221 Raw Casting Suppliers Process Outputs Customers 24245 Machine Main Valve Seat Acceptable 24245 Mexicali Texas Die Casting Modern Metal China Precision Receive Inspect Raw Casting Inspect Main Valve Seat Define Section 4 Climate Controls OEM Products Group Project Overview : Customer is frustrated by failures due to the Main Valve Seat defects. • 2% Rejects 20,000 assemblies - 400 rejects daily. • Excessive rework to main valve seat. • Excessive returns to the Long Beach. Define Section 5 Climate Controls OEM Products Group Executive Summary: Reduce the Main Valve Reworks/Returns Create a process that is 1.67 Cpk capable Define Section 6 Climate Controls OEM Products Group Goal: • Reduce current 24245 PPM Returns to < 500 PPM • Savings to Mexicali $25,000 annually • Savings to Long Beach $ 40,000 annually Projected Improvement: • Reduce failures during Mexicali Assembly and test • Create more robust machining and inspection of the main valve seat Define Section 7 Climate Controls OEM Products Group Six Sigma: TEAM CHARTER Product Impacted 110 Body Product Impacted Sales (’03 proj $) Blackbelt X Greenbelt � Peter Wright Telephone Number 1-310-900-2395 Champion Kevin Kidder SBU & Plant Water Heating Start Date Feb. 18, 2002 Target Completion Date 30 Sep 2002 Element Description Team Charter 1. Process / Product: The production process in which opportunity exists. Kingsbury main valve machining. Machining defects on main valve resulting in leaking of main valve seat. 2. Project Description: Describe the Project’s Purpose and scope. To reduce the Defects on the main valve seat for Part Number24245. 3. Objective: What improvement is targeted and what will be the impact on RTY, COPQ and C-P? Base line Actual Goal Entitl e- ment units See attached Definition sheet for examples Quality Metrics: RTY, DPU, DPPM Quality 2% 2% .2% .1% RTY Cost of Poor Quality COPQ $65k $65k $2.5k $1.25k dollars 4. Business Results: (in 2000 Dollars) What is the improvement in business performance (eg- sales and income) anticipated and when? Reduction of the rejects at Mexicali will result in less disassembly higher RTY, thus a reduction in the COPQ due to this defect. Estimated payback for the two plants is $62.5k per year, effective Fiscal year 2003. 5. Team members: Who are the full-time members and any expert consultants? Kevin Kidder – Champion Leonel Garcia – Customer Ricardo Partida – Quality Engineer 110 Line 6. Project Scope: Which part of the process will be investigated? Main Valve Seat 24245 7. Benefit to External Customers: Who are the final customers, what benefit will they see and what are their most critical requirements? Rheem, American Water Heating benefit will be longer life and less returns due to leaking on gas from the main valve seat. 8. Schedule: Give the key milestones/dates. Project Start 2/15/2002 Focus on projects M- Measurement “M” Completion 3/15/2002 that can be finished A- Analysis “A” Completion 4/15/2002 In 4-6 months max. I- Improvement “I” Completion 6/15/2002 C- Control “C” Completion 7/15/2002 Note: Schedule appropriate Safety Reviews. Safety Reviews Project Completion 8/15/2002 9. Support Required: Will you need any special capabilities, hardware, etc? New machine for machining the main valve seat. New optical inspection equipment for inspecting the dimension and defects in the main valve seat area. Project Charter 24245 Main Valve Seat Define Section 8 Climate Controls OEM Products Group Measure Project DMAIC REVIEW DEFINE MEASURE ANALYZE IMPROVE CONTROL Data Collection Data Analysis Process Sigma Process Analysis Measure Section 9 Climate Controls OEM Products Group Damaged Main Valve Seat Acceptable Main Valve Seat Measure Section 10 Climate Controls OEM Products Group Start Parts Machined in Long Beach OK? Scrap/Rework Parts KPIVs Measurement KPOVs N Package & Ship OK? Return to Long Beach N Y Assembly & Test Y SOP Microscope RTY Scrap $$ Process Cpk SOP MacPac Quantity Right P/N ? Right Address? SOP Microscope PPM RTY $$ returned SOP RTY Ass’y drawing Work instructions Specification SOP Cycle time Reject rate Scrap $$$ Drawing Work instructions Work instructions Ass’y drawing Work instructions Ass’y drawing Work instructions OK? N Return to Long Beach Y 1 Measure Section 11 Climate Controls OEM Products Group Package and Ship KPIVs Measurement KPOVs SOP Microscope RTY Scrap $$ Process Cpk Drawing Work instructions 1 RTY Scrap $$ Process Cpk Customer Satisfaction OK? Return to Mexicali N Y Measure Section 12 Climate Controls OEM Products Group 22.9% Fuga externa 14.09% F. valvula Ppal. Baj 7.98% F. Gas Ppal. Pos. Pi 5.97% Rango Corto 5.91% TV, TV2, TVO 5.79% Fuga x GC 4.77% Rango Largo 4.46% F. Valvula Ppal. Alt 4.16% Piloto Reg. 3.55% Fuga Valv. Mag. PARETO DEFECTS FOR W0-W9 FROM 09/01/2001 TO 03/12/2002 DEFECT CODES F u g a e x t e r n a F . v a l v u l a P p a l . B a j F . G a s P p a l . P o s . P i R a n g o C o r t o T V , T V 2 , T V O F u g a x G C R a n g o L a r g o F . V a l v u l a P p a l . A l t P i l o t o R e g . F u g a V a l v . M a g . 30% 20% 10% 0% 22.9% 14.09% 7.98% 5.97% 5.91% 5.79% 4.77% 4.46% 4.16% 3.55% RTY F. Valvula Ppal. Baja = Main Valve Leak External Leak Multiple possibilities for this defect Main Valve Leak Specific Measurable Action Oriented Realistic Time & Results Constraints Analyze Section 13 Climate Controls OEM Products Group DMAIC REVIEW DEFINE MEASURE ANALYZE IMPROVE CONTROL Identifying Causes Verifying Causes Selecting Solution Analyze Section 14 Climate Controls OEM Products Group Main Valve Seat Leaking Damage In Long Beach Tooling is old Incorrect Set up Lead man setup wrong RPM Feed Measurement errors Incorrect gage for measuring intend Poor Gage R&R Environment on Gage No budget available to buy Operator preferences Operators used all tolerance width Target set-up differ from Operator-to-operator Machine complement (run multi machine To achieve production target Lack of customer- focused � Machine causing damage to parts Damage in Mexicali Damage while removing chips Handling during unpacking Not Done in Long Beach Poor Assembly Practice TREE DIAGRAM Management goal Unknown of impacts (due to large variation) WHY? WHY? WHY? WHY? WHY? Handling Washer Container Dirty No budget available to buy Poor attitude During Assembly Not Done in Long Beach Management decision Management decision High Turn over rate Cost Cost Salary competiveness Tree Diagram – Main Valve Seat Analyze Section 15 Climate Controls OEM Products Group • Brainstorming - Solutions • Recharge Tooling more often • Speak to supervisor about attitude of operator • Neoprene plugs • Cleans containers • Stop inspection and remove plug at operation 210 of assembly • Review inspection criteria Improve Section 16 Climate Controls OEM Products Group Tree Diagram – Main Valve Seat DMAIC REVIEW DEFINE MEASURE ANALYZE IMPROVE CONTROL Brainstorm Select Solution Develop Detailed Plans Pilot Implement according to the plan Evaluate the methods and results Improve Section 17 Climate Controls OEM Products Group • Brainstorming - Causes Tooling bad Operator doesn’t care Handling damage during process Containers Mexico is damaging during inspection/assembly Over critical Improve Section 18 Climate Controls OEM Products Group • Engineering Change Request to change frequency of recharging tool • Work Instructions updated to recharge on every shift • This is done to prevent black residue on main valve seat and building up on the tool damaging the part. Improve Section 19 Climate Controls OEM Products Group • Purchase Neoprene Protective Plug • Three vendors • Given same specification • Purchase Order given to Real Seal • 10,000 pieces and tooling $4,282 (6- 8 week delivery) from 5-8-02 • Received Plugs August 12, 2002 (4 weeks overdue) • ROI six month Control Section 20 Climate Controls OEM Products Group Tree Diagram – Main Valve Seat DMAIC REVIEW DEFINE MEASURE ANALYZE IMPROVE CONTROL Document new method Train Monitor implementation Continually update and improve the method Control Section 21 Climate Controls OEM Products Group • The Process Sigma has improved from 3.8 to 5.0 because of the daily recharging of the tooling. Effective September 3,2002 based on data from January 2002. • The Process Sigma is expected to meet the 6 Sigma level once the Protective Plugs are received and used on a daily basis Control Section 22 Climate Controls OEM Products GroupMonth Process Sigma January 3.7 February 3.7 March 3.8 April 3.8 May 4.8 June 4.9 August 5 September 6 November 6 December 6 Process Sigma Main Valve Seat 3.7 3.7 3.8 3.8 4.8 4.9 5 6 6 6 0 1 2 3 4 5 6 7 Ja nu ar y Fe br ua ry M ar ch Ap ril M ay Ju ne Au gu st Se pt em be r No ve m be r De ce m be r M th S i g m a Based on Process Sigma Formula Data collected weekly in Mexicali Control Section 23 Climate Controls OEM Products Group • Training Performed training with updated Work Instructions with all operators three shfts on the method and frequency of recharging the tool. Control Section 24 Climate Controls OEM Products Group End Results • The plugs were installed after the washer operation. • 1,100 parts were shipped to Mexicali on August 22nd. Assembled on the 23rd. – First fixture would not allow part with plug. – Requested fixture modification – Fixture modified on September 3rd. – 2 parts of 1,100 defective - Control Section 25 Climate Controls OEM Products Group End Results (continued) • 1,100 parts were shipped to Mexicali on September 5th. Assembled on the 6th. • No defects found! Success. Control Section 26 Climate Controls OEM Products Group End Results Photos Containers to return Plugs Operators installing plugs after the parts are washed. Control Section 27 Climate Controls OEM Products Group End Results Photos Operators installing plugs after the parts are washed. Parts stacked in container ready for shipment Fixture after modification Mexicali Plant Control Section 28 Climate Controls OEM Products Group End Results Photos Subsequent operations. No problems Plugs removed before cover is put on. No damage to part.