Cluster+Bezel+091709+Final

1 Johnson Controls, Inc. © June 2007

ASG-NA Automotive NorthwoodProcess Owner: Brian KrugerGREENBELT: Randall RichardsonMaster Black Belt: Fernando BuchholzSigma Trac ID # 200807163834

Project Schedule

Definition: 08/15/08 09/24/08 09/27/08 Measure: 09/19/08 11/05/08

11/25/08Analyze: 10/10/08 01/10/09

01/23/09Improve: 11/10/08 02/18/09 04/10/09 Control: 11/28/08 04/29/09 04/29/09Validation: 07/29/09 07/29/09

07/29/09

Original Revised ActualCompletion Completion

Completion

BUILD COCKPITS – Reduce the number of Cluster Bezel Repairs in the Tester area


• Problem Statement:There is non value added work being performed at the end of line testers.

For the month of June 2008 there were 12 cluster bezel repairs made to the Cockpits. This resulted in a scrap cost of $155.64 (annualized at $6225.6), and a downtime cost of $256 (annualized at $10,240) in man hours. This information is gathered from the repair logs.

• Project Objective:YC1 = (Number of Cockpits that should have been repaired or contained but

were sent to the testers)YB1 = cost of downtime due to repairs in testersYB2 = cost of scrap due to repairs in testersYp1 = proportion of bezels repaired / week

Define


Drill Down Pareto

Count 112 4 4 2 2 2 1 1Percent 3.441.4 13.8 13.8 6.9 6.9 6.9 3.4 3.4Cum % 100.041.4 55.2 69.0 75.9 82.8 89.7 93.1 96.6

Tester Repairs

302520151050

100

80

60

40

20

0Co

unt

Perce

nt

Pareto Chart of Tester RepairsCount 31 8 8

Percent 66.0 17.0 17.0Cum % 66.0 83.0 100.0

REPAIREQ TESTER 6 DOWNRP

50

40

30

20

10

0

100

80

60

40

20

0

Coun

t

Perc

ent

Pareto Chart of TESTER JUNE DOWNTIME

Total repairs at tester June 2008

Count 12 5 5 5 2Percent 41.4 17.2 17.2 17.2 6.9Cum % 41.4 58.6 75.9 93.1 100.0

Cluster Bezel Repair Types

30

2520

1510

50

100

80

60

40

20

0

Coun

t

Perc

ent

Pareto Chart of Cluster Bezel Repair Types

Scratches #1 repair


Statement of Work

CI Statement of WorkDate printed: 9/9/08

Form rev.: 2007-0328a

Project Title:

Location:

Phase Definition Project # 200807163834Originator: Jay LewisCustomer Quality Focus: YesCreate Date: 7/31/08

Rollout Type:

PROJECT DESCRIPTIONProcess / Product Being Improved: Project Scope and Boundaries: Customer Y (s):

Business Y (s):

Problem Statement:

Project Objective / Suspected Root Cause: Primary BBP metric impacted:BBP Product Line:

ESTIMATED SAVINGS (from COPQ)Est. Hard Savings: Est. Soft Savings: 78

TEAMProcess Owner: Denise Stinson Black Belt:

CI Manager: Jay Lewis Green Belt: Randall R Richardson

Yc1 = Number of Cockpits that should have been repaired but were sent to customer.

Interiors: Instrument Panels

Yb1 = Cost of doing repairs in testers.

There is non value added work being performed at the end of line testers. For the month of June 2008 there were 34 repairs made to the Cockpits. The information is gathered from the repair logs. Reduce the number of repairs being sent to the testers by 85%.

10 - Total Labor Hours Per EQU

2009 Q1 BUILD COCKPITS - Reduce Number Of Cockpits Needing Repair At TestersUSA - Northwood OH

Cockpit assembly process.

AG - NAJ IT - DCBU - Northwood - Cockpit Line

Standard

200807163834

Type: Green Belt

#N/A#N/A

Objective: Reduce number of defective cluster bezels being sent to the Testers by 100%.

Process: Build Cockpits

Problem: There is non value added work being performed at the end of line testers. For the month of June 2008 there were 12 cluster bezel repairs made to the Cockpits. This information is gathered from the repair logs.

YC1= Number of Cockpits that should have been repaired but were sent to the testers

YB1 = Downtime cost due to repairs in testers

YB2 = Scrap cost due to repairs in testers

YP1 = proportion of cluster bezels repaired / week

5

Baseline Performance

Level

Description(with unit of measure) Before

Project Target After % Improve

YC panels repaired/each 12 0

YB1

Annualized cost of dow ntime due to repairs in testers in dollars $10,240.00 0

YB2

Annualized cost of scrap due to repairs in testers in dollars $6,225.60 0

Avg:0.009 Avg:0 Avg:St.Dev:.005 St.Dev:0 St.Dev:Cpk or P pk:N/A

Cpk or P pk:N/A

Cpk or P pk:

Proportion of bezels repaired per day (p bar)

YP

6

Customer Y

YC1 = No. of unacceptable cluster

bezel scratches found in tester area

12/29 unacceptable repairs for scratched

bezels(41.4% of total occurrences)

FY08 data from the month of June scrap report

Count 12 5 5 5 2Percent 41.4 17.2 17.2 17.2 6.9Cum % 41.4 58.6 75.9 93.1 100.0

Cluster Bezel Repair Types

3025

20

1510

50

100

80

60

40

20

0

Coun

t

Perc

ent

Pareto Chart of Cluster Bezel Repair Types

7

Business Y

YB2= Cost of scrap due to repairs (cluster bezels) in testers Process in statistical control. Operating within control limits

YB1= Cost of downtime due to repairs in testers

Process in statistical control.Operating within control limits

06/0806/0706/0606/0506/0406/02

$250.00

$200.00

$150.00

$100.00

$50.00

$0.00

-$50.00

-$100.00

Date

Indi

vidu

al V

alue

_X=$56.20

UCL=$235.58

LCL=-$123.17

I Chart of Cost of scrapped bezels

06/0806/0706/0606/0506/0406/02

$150.00

$100.00

$50.00

$0.00

-$50.00

Date

Indi

vidu

al V

alue

_X=$42.65

UCL=$147.01

LCL=-$61.71

I Chart of Downtime Cost


Concentration Chart

scuff marks on A surface

scratches on A surface

KA chart of scratch location

on A surface

KK chart of scratch location

on A surface


Initial Process FlowCluster Bezels are received from

shipping and stored in storage area

panel moves to stn 25 (steering shroud installed) and then to the tester area to be tested and stored in th

HK system waiting to be shipped to customers

material handler retrieves and scans

part

Places part on belt

Finds correct part and scans it

stn 20 operator retrieves part from

belt

stops line and finds correct

part

places part in tote box

stn 24 operatro retrieves part from

tote and scans label on part

installs cluster bezel to IP shell

Yes

No

No

Yes

stops line and retrieves correct part

and scans it

No

Yes

Finds correct part and

scans it for verification

Stops line and retrieves correct

part and then scans for

verification

Stops line and retrieves correct part

and then scans for verification

Project focuses on this part of the process

10

Yp1 Current Defective

Level = 4603 PPM

Historical Data

Acceptable MSA

Process YYC1 = Number of Cockpits that should have been repaired but were sent to customer

YP1 = (proportion of bezels repaired / week)Between Appraisers

Assessment Agreement

# Inspected # Matched Percent 95 % CI 30 28 93.33 (77.93, 99.18)

# Matched: All appraisers' assessments agree with each other.

11

View of Process Before Changes

Stacking parts on top of each other

Station 20 bezel kit area


4 Identify causes (Xs) of variation and defects.Yp1 = No. of defective cluster bezels being sent to testers

People

MachinesMethods

Materials

Scratched cluster bezels

Operators in a hurry

Operators tossing bezel in tote

New tasks added to process

Material/operator Handlers stacking parts on top of each other during part change out

Height of torque gun stn 24

Shipments received from supplier

Potential Causes

Tote is close to empty, time to change out tote for more

parts

Replacing stripped unuts

Operator drove screw into bezel incorrectly

Bit from torque gun scratching after torque process

X1

X3X2

13

Potential CauseNull

HypothesisAlternative Hypothesis Verification Data

Data Type (Attribute/Variable)

Verification Method (Test)

Results (P=) Conclusion

(Reject Null?)

Verified Cause? (Y/N)

Y1 X1 Operator tossing besel into tote P > 0 P < 0Collected data for 1 shift to determine # of bezels returned for scratches Attribute

2 Proportion Test P=1 No

Y1 X2Material Handler/Operator stacking parts on top of each other P > 0 P < 0

Collected data for 1 shift to determine # of bezels returned for scratches Attribute

2 Proportion Test P=0.000 YES

X3Bit from torque gun scratching bezel after torqueing process P > 0 P < 0

Collected data for 1 shift to determine # of bezels returned for scratches Attribute

2 Proportion Test P=0.158 NO

Verified Causes

Verified XsX1 P value above .05X2 proved to be significant (P value 0)X3 P value above .05

YP1 = proportion of bezels repaired/week

14

Very effective, easy to implement, low costModerately effective, Moderately easy to implement, Moderate cost

Not very effective, Hard to implement, High cost

LEGEND

YP1 = Proportion of bezels repaired/per week

Cause Possible Counteractions

Effectiveness

Ease to Im

plement

Cost

SafetyY1 X2 material

handler/operator stacking parts on top of each other

Using empty spaces in other totes to lodge excess bezels during changeoutsI9 Cross-train managers to take food orders (second back-up)

X2 material handler/operator stacking parts on top of each other

Fast Tube Rack


Corrugated Sleeve Rack to store bezels during changeout

I12 Simplify/standardize abbreviations on print-out


Training, making operators aware of the problems associated with staking bezels on top of each other

X10 Slammed (restaurant extremely busy)

Cross training identified for X7 and X8

X12 Inadequate prep (not enough items prepared ahead of time)

I14 Modify computer programming to bucket "prepared" items into lunch and dinner groups, head cook to publish schedule 1 day in advance

Potential Counteractions

X Counteractions

Operator stacking corrugated sleeve

parts on top of each Rack

other

15

New Process FlowBefore After

X2

Cluster Bezels are received from shipping and stored in storage

area




part

Places part on belt



belt


part





Yes

No

No

Yes


and scans it

No

Yes

Cluster Bezels are received from shipping and stored in storage

area




part

Places part on belt



belt


part





Yes

No

No

Yes


and scans it

No

Yes

Utilizing corrugated sleeve rack in preparation for cluster bezel part change outs

Finds correct

part and scans it for verification

Stops line and retrieves

correct part and then scans for verification



verification

Finds correct

part and scans it for verification

Stops line and retrieves

correct part and then scans for verification



verification

16

View of area after improvementCorrugated sleeve rack

built/installed

Rack creates a buffer from the time the operator calls for new parts to the time the forklift operator actually arrives to replace empty totes. This way operator is not forced to stack parts on top of each other.


Before/After Charts

Improve

YC1 = Number of Cockpits that should have been repaired but were sent to customer

YP1 = (proportion of bezels repaired / week)

100% improvement


Before/After Charts

Improve

YB1 (Cost of downtime due to repairs in testers)

04/0804/0704/0604/0204/0106/0706/0606/0506/0406/02

$150.00

$100.00

$50.00

$0.00

-$50.00

Date

Indiv

idual

Value

_X=$0.00UCL=$0.00LCL=$0.00

before afterI Chart of Downtime Cost by Condition

100% improvement


Before/After Charts

Improve

YB2 (Cost of scrap due to repairs in testers)

$250.00

$200.00

$150.00

$100.00

$50.00

$0.00

-$50.00

-$100.00

Date

Indiv

idual

Value

_X=$0.00UCL=$0.00LCL=$0.00

Before AfterI Chart of Cost of scrapped bezels by Condition

100% improvement


PFMEA

Control

RPN Lowered from 294 to 42 based on occurrence score going from 7 to 1


Control Plan

Control

Instructions on staging rack added to ODS


ODS

Control

KK KA

Process Steps

Class Photos

× × 1 Scan track sheet.

× × 2

Verify remote start is connected to WCM, observe correct plug orientation as shown and scan "YES" bar code. Load WCM onto steering column (Option).

× × 3 Retrieve and scan SCCM switch.

× × 4 Make (3) connections to bottom of SCCM.

× × 5 Torque down WCM with (1) 6508440AA torx screw.

× × 6 Load SCCM onto steering column.

× × 7 Drive the first torque into the front of the SCCM.

× × 8 Drive (2) torques in order 'a' then 'b' as shown in picture.

× × 9 Make (1) connection to the top of the SCCM.

× × 10 Retrieve the cluster bezel either from conveyor or lineside ropak, then lay on kit tote.

× × 11 In preparation for cluster bezel part change out use staging rack.

× × 12 Release Cart

5 "S" Checklist

ALL Operators have the authority to STOP the line for NON-CONFORMING PRODUCT, or if there is a SAFETY ISSUE. The Operator must contact Supervisor immediately.Do Not Try and Retrieve anything dropped into the equipment without following the proper safety procedures including stopping the equipment and asking for assistance when needed.

ApprovalsDuring each rotation. . . Materials________________________ Date

1) Straighten out parts, and put all tools in their proper places. Quality Date

2) Dust all equipment.Total Productive Maintenance -- Notify your Supervisor if any issues are foundVisually check and inspect all tools and equipment for any visable damage. Verify that all work surfaces including belt conveyors are clean to prevent dirt getting on seats.

Safety Date

3) Clean and sweep floor around work area.

Engineering Date

4) Dispose of all scrap & trash in proper containers.

Production Date

5) When complete call line supervisor for inspection. "Continually Exceed Our Customer's Increasing Expectations"

Revision Date: 05/05/2009

Utilizing the staging rack implemented into the ODS

23

Results Summary

Scrap Cost calculation $12.97 * # of scrapped bezels

Description(with unit of measure) Before

Project Target After % Improve

YC panels repaired/each 12 0 0 100%

YB1

Annualized cost of dow ntime due to repairs in testers/dollars $10,240.00 0 0 100%

YB2

Annualized cost of scrap due to repairs in testers/dollars $6,225.60 0 $0.00 100%

Avg: .009 Avg:0 Avg: 0St.Dev:.005 St.Dev:0 St.Dev: 0Cpk or P pk:N/A

Cpk or P pk:1.33

Cpk or P pk:N/A

proportion of bezels repaired per week/dollars

YP

Downtime cost calculation formula – [1.71 minutes * 18 *# of Ops]/60 *18.5


Before/After Charts

3 Month Validation

YC1 = Number of Cockpits that should have been repaired but were sent to customer

YP1 = (proportion of bezels repaired / week)

08/2808/2408/1108/0507/3004/1904/1504/0904/0206/0605/23

0.035

0.030

0.025

0.020

0.015

0.010

0.005

0.000

Date

Prop

ortio

n

_P=0UCL=0LCL=0

Before After1

Cluster Bezel ScratchesBefore and After

Tests performed with unequal sample sizes

100% improvement continues


Before/After Charts

3 Month Validation

YB1 (Cost of downtime due to repairs in testers)


08/2808/2508/1308/1008/0507/3107/2804/0704/0106/0606/02

0:03:00

0:02:00

0:01:00

0:00:00

-0:01:00Date

Indiv

idual

Value

_X=0:00:00UCL=0:00:00LCL=0:00:00

before afterI Chart of Downtime by Condition


Before/After Charts

3 Month Validation

08/3108/2508/1208/0607/3107/2704/1604/1004/0604/0606/0706/02

20

15

10

5

0

-5

-10

Date

Indiv

idual

Value

_X=0UCL=0LCL=0

Before AfterI Chart of Scrapped bezels by Condition


YB2 (Cost of scrap due to repairs in testers)

Documents

Cluster+Bezel+091709+Final