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ConMed Chihuahua Six Sigma Green Belt
Training – 2st.Wave
Chihuahua, MexicoJanuary 2013
Project
Team Members …
• Oscar Macias GB leader• Jose Luis Sanchez• Alfredo Roacho • Gildardo Parra - Champion • Eduardo Rodriguez• Cristina Castillo• Manuel Saucedo• Jorge Marquez• Ruben Vizcarra Black Belt
Scrap Reduction by contamination in tube.at Extruder # 1 & 2
September 2012 - January, 2013
Define
Measure
Measure
Attributes agreement analysis
Resina cruda Interna 1Punto negro 2Resina quemada 3Resina cruda externa 4Pieza bien 5
21
100.0
97.5
95.0
92.5
90.0
87.5
85.0
Appraiser
Perc
ent
95.0% CIPercent
21
100.0
97.5
95.0
92.5
90.0
87.5
85.0
Appraiser
Perc
ent
95.0% CIPercent
Date of study: Reported by: Name of product: Misc:
Assessment Agreement
Within Appraisers Appraiser vs Standard
Measure
Gage R&R Study - ANOVA Method Only with bag
Part-to-PartReprodRepeatGage R&R
100
50
0
Perce
nt
% Contribution% Study Var
1.0
0.5
0.0
Parts
Samp
le Ra
nge
_R=0.45
UCL=1.158
LCL=0
1 2
24
16
8
Parts
Samp
le Me
an
__X=12.1UCL=12.56LCL=11.64
1 2
2019181716151413121110987654321
24
16
8
Parts
21
24
16
8
Operators
24
16
8
Parts
Avera
ge 12
Operators
Gage name: Date of study:
Reported by: Tolerance: Misc:
Components of Variation
R Chart by Operators
Xbar Chart by Operators
Appraisers by Parts
Appraisers by Operators
Parts * Operators Interaction
Gage R&R (ANOVA) only with bag
18
12
6
18
12
6
18
12
6
1
Operators
C6
2 3 4 5 6 7
Mean
8
Mean
9 10 11 12 13 14
15 16 17 18 19 20
Mean
12
Operators
Gage name: Date of study:
Reported by: Tolerance: Misc:
Panel variable: Parts
Gage Run Chart of C6 by Parts, Operators
Measure
Gage R&R Study - ANOVA Method With car
Part-to-PartReprodRepeatGage R&R
100
50
0
Perc
ent
% Contribution% Study Var
2
1
0
Parts
Sam
ple R
ange
_R=0.575
UCL=1.480
LCL=0
1 2
24
16
8
Parts
Sam
ple M
ean
__X=12.25UCL=12.84LCL=11.66
1 2
2019181716151413121110987654321
24
16
8
Parts
21
24
16
8
Operators
24
16
8
Parts
Aver
age 1
2
Operators
Gage name: Date of study:
Reported by: Tolerance: Misc:
Components of Variation
R Chart by Operators
Xbar Chart by Operators
C6 by Parts
C6 by Operators
Parts * Operators Interaction
Gage R&R (ANOVA) with car
40
32
24
40
32
24
40
32
24
1
Operators
con c
arrit
o
2 3 4 5 6 7
Mean
8
Mean
9 10 11 12 13 14
15 16 17 18 19 20
Mean
12
Operators
Gage name: Date of study:
Reported by: Tolerance: Misc:
Panel variable: Parts
Gage Run Chart of con carrito by Parts, Operators
Measure
Analyze
Affinity Diagram
extrusorasende build upGeneracion
Medio ambiente
Medicion
Metodo
Material
Maquinaria
Mano de obra
Turnos
Falta de entrenamiento
Arreglo de temperaturas inadecuadas
Presion inadecuada
Melt inadecuado
Herramientas de limpieza no disponibles
Plato rompedor dañado
Pin, dado y cabezal dañado
Tornillo dañado
herramientas no adecuadoMaterial para limpieza de
particulas negrasMaterial contaminado por
Diferentes tamañosn de Pellets
no uniformePellets deformados/ Formacion
Limpieza de plato rompedor
Acumulamiento de material
Limpieza de dado, pin y cavezal
Rango de temperaturas
Limpieza de extrusora
Gaylord descubierto
Descomprimir resina con remo
Gage para medir cucaracha
cajasGeneracion de particulas de las
Cause-and-Effect Diagram
Analyze
6’M why? hypothesis
Cause demonstration of hypothesis
Material
Pellets improperly formed/ pellets
with different size
Inadequate cleaning materials
Absence of inventory control / lack of material
contaminated by black particles
Material burned in the development
of pellets
Analyze
t
W
Analyze
Extruder 1Analyze
Extruder 1
Analyze
Extruder 2
Analyze
Extruder 2
Analyze
Analyze
Analyze
California TennesseeAnalyze
Lack of material
Analyze
• During the preview measurement not founded black particles in 250 gaylords
Analyze
6’M why? hypothesis
Cause Demonstration of hypothesis
Personnel
Poor training
Different knowledge
between operators
ShiftsDifferent technique
of operators by shift
Analyze
Extruder 1
Extruder 2
Cabezal
Cabezal
Cabezal
Cabezal
Analyze
Extruder 1
Extruder 2
Analyze
Extruder 1
Extruder 2
Cabezal
Cabezal
Analyze
Extruder 1Analyze
Extruder 2Analyze
6’M Why?Hypothesis
Cause Demonstration of hypothesis
Method
Cleaning of Screen plate
Material accumulation
Absenteeism/ unbalanced
Temperature range
Uncover Gaylord
Unsuitable top
Assembly of die in head
Having a bad assembly of die will cause leaks
resulting resin burned in the die
Analyze
Analyze
Extruder 1
Extruder 2
Analyze
Extruder 1Analyze
Extruder 2Analyze
Analyze
Analyze
Analyze
Analyze
Nominal Parameters 1/4 ID 125 fpm Line Speed
290
295
300
305
310
315
320
325
Barrel # 1 Barrel # 2 Barrel # 3 Barrel # 4 Barrel # 5 Barrel # 6 Barrel # 7 Clamp Dado # 1 Dado # 2
Recommended parameters apply to an of extruder 7-barrels
0
50
100
150
200
250
300
350
Barrel #1
Barrel #2
Barrel #3
Barrel #4
Barrel #5
Barrel #6
Barrel #7
Clamp Dado #1
Dado #2
Tem
pera
ture
F
←Extruder 1
Extruder 2→
Analyze
Extruder 1Extruder 1
Analyze
Extruder 2Extruder 2
Analyze
Analyze
Analyze
Analyze
6’M Why?Hypothesis
CauseDemostration of hypothesis
Measurement Not gage for
build up measurement
N/A
Analyze
6’M Why?Hypothesis
Cause Demonstration of hypothesis
Environment Generation of carton particles
Uncontrolled
environment
Analyze
Analyze
6’M Why?Hypothesis
Cause Demonstration of hypothesis
Machine
Screen plate, Die, Head, Pin and Screw
Damage
The surface of all tooling through which flows the resin must be completely
smooth without scratches or damage if there is damage in the tooling, the resin will
accumulate in cracks or rough surfaces and burned in that area.
Tools Cleaning not available
If you do not have the right tools for cleaning machinery and equipment not cleaned
properly You might still leave in the tooling, burned material
Melt inappropriate
Recommended melt for the PVC Flexible resin
Pressure Inappropriate
Analyze
Extruder 1
Extruder 1Analyze
Extruder 1
Analyze
Extruder 1Cabezal
Cabezal
Analyze
Extruder 2
Extruder 2Analyze
Extruder 2
Analyze
Extruder 2Cabezal
Cabezal
Analyze
Analyze
Analyze
Analyze
Extruder 1
Analyze
Extruder 2Analyze
Extruder 2Analyze
Analyze
extruder 1
Analyze
extruder 2
Analyze
Screen pack Arrey Ex. 1
←Time
Size→
Analyze
←Melt
←Pressure
Analyze
Screen pack Arrey Ex. 2
←Time
Size→
Analyze
←Melt
←Pressure
Analyze
IMPROVE
• Material Improvements.
Improve
CauseImprove
Pellets improperly formed/ pellets
with different size
Inadequate cleaning materials
1. Apex Teknor provide the material until of Tennessee they fix the process in California, the date must be no longer than one month.
2. Is added to CIP 1003791 the size and shape of pellet uniform even with photographs.
1. We implemented a Kanban system for chemical inventory and is documented in the EWI-068-M
Improve
Improve
Improve
CauseImprove
Cleaning of Screen plate
Temperature range
Uncover Gaylord
1. We standardized the method of cleaning the plate breaking and documented in the EWI-068-M
2. The area was fitted with the necessary tools to properly clean your plate and inspect the work
Method Improvements.
1. Validation of the extruder # 2 in temperature ramp-
Improve
Assembly of die in head
Improve
Improve
Improve
We standardized the method of assembly of die and the procedure is documented in
EWI-068-M
Improve
Improve
CauseImprove
Machine Improvements.
Screen plate, Die, Head, Pin and Screw
Damage
Melt inappropriate
Pressure Inappropriate
1. Validation of the extruder # 2 in temperature ramp-
1. We implemented the arrangement # 2 mesh to increase the pressures over 1000psi and is documented in the EWI-068-M set up of extruders.
Identify each tooling, die and pin and will be creates a
verification and replacement procedure.
This Procedure is documented in the EWI-068-M
Improve
Improve
Improve
White Room Improvements.
Implementar recorrido semanal 15 minutos con Supervisor e Ingenieros para revision de area y filtros
Yosselyn Eslava / Oscar Macias / Luis Carrera / Jose Luis Sanchez / Miguel Baez
Continuo a partir del 27-
Sep-12
27 Sep: Se realiza primer recorrido. Ver anexo C.4 Oct: Se realiza segundo recorrido. Ver anexo.
Auditoria de areas de tecnicos de STB (equipo, gavetas)
Carolina Carmona 27-Sep-12
27 Sep: Completado el 24 de sep. Ver anexo D.4 Oct: Se lleva semanalmente. Se anexaran auditorias a reporte, se encuentran los tecnicos en espera de que llegue el carro SMED.
Implementar en sistema TMS Mantenimientos programados para limpieza del exterior del equipo de extrusion
Roel Ramirez Done 27 Sep
Proponer junta con Nico / Rogelio / Roel para disposicion de equipo
Oscar Macias / Yosselyn
Eslava / Luis Carrera
27-Sep-12
27 Sep: Nico trae esa actividad. Gerardo esta investigando que se puede ir y que no, en espera de respuesta (Claudia) 12 oct
Improve
• Validating Improvements.
Improve
JAN FEB MAR APRIL MAY JUNE JULY AUGUST SEP OCT NOV DEC
EXTRUD
E
0 UNCLASSIF
1 BAD MATERIAL
2OPERATOR ERROR
3ENGINEERING ERROR
4 QA SAMPLE
5 TEST MATERIAL
6SCRAP DUE TO MACHINE SET UP
$ 14,393.65
$ 14,432.12
$ 12,204.77
$ 8,529.78
$ 9,786.12
$ 5,973.11
$ 9,655.07
$ 11,896.28
$ 6,646.28
$ 4,848.35
$ 5,108.39
$ 3,045.88
7
OBSOLETE VIA ECN &/OR MARKTNG
8MACHINE MALFUNCTION
9 RGA MATERIAL
TOTAL EXTRUDE
$ 14,393.
65
$ 14,432.1
2
$ 12,204.7
7 $
8,529.78 $
9,786.12 $
5,994.84 $
9,655.07
$ 11,896.2
8 $
8,003.65 $
6,678.85 $
5,108.39 $
3,045.88
Cost Material
$ 383,683.53
$ 553,397.
09
$ 428,925.
39
$ 419,695.
35
$ 529,390.
69
$ 401,317.
95
$ 400,704.
96
$ 495,986.
88
$ 370,875.
97
$ 477,810.
72
$ 363,633.
21
$ 273,533.
50
% Scrap 3.75% 2.61% 2.85% 2.03% 1.85% 1.49% 2.41% 2.40% 1.79% 1.01% 1.40% 1.11%
Sem
ana
# 36
Sem
ana
# 37
Sem
ana
# 38
Sem
ana
# 39
Sem
ana
# 40
Sem
ana
# 41
Sem
ana
# 42
Sem
ana
# 43
Sem
ana
# 44
Sem
ana
# 45
Sem
ana
# 46
Sem
ana
# 47
Sem
ana
# 48
Sem
ana
# 49
Sem
ana
# 50
Sem
ana
# 51
0
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
Scrap por Semana de Extrusion
Libr
as
Meta: 890 Lbs
Improve
Economic Benefits of ProjectBaseline:
Historical data (Scrap average first 9 months): $ 2,380.60 dlls per month. 0.53% of Scrap by contamination$ 28,567 dlls anual
Achieved 0.079% of Scrap by contamination
85 % of improvement This improvement represents a potential saving of $24,282 dlls from the $28,567 historical data.
• PFMEA Update
Improve
– Mitigation of potential causes that generates scrap.
• Daily scrap monitoring.Control
Daily meeting to review scrap
Control
• Plan Control Update
Control
• Follow up Activities
ActividadStatus Fecha de terminacion Responsible
Actualizacion del CIP de la resina 1003791En Proceso
28 de Enero del 2013 Cristina Castillo
Implementacion de Kanban de Quimicos y Elaborar el procedimiento En Proceso 24 Enero Del 2013 Oscar Macias
Validacion de Extrusora 2 Temperaturas Tipo Rampa 3 corridas de OQ y 3 Corridas de PQ En Proceso 14 De Febrero del 2013 Oscar Macias
Implementar todas las tapas de los gaylors En Proceso 28 de Enero del 2013 Oscar Macias
Documentar la mejora del ajuste de dado con torque establecido a 5lbf En Proceso 31 de Enero del 2013 Oscar Macias
Mandar a Identificar los dados, pines y platos rompedores y elaborar procedimiento de reemplazo
En Proceso 7 Febrero del 2013 Oscar Macias
Documentar el arreglo de mallas para elevar la presion de extrusion a mas de 1000 Psi En Proceso 31 de Enero del 2013 Oscar Macias
Questions?