Downtime Reduction Downtime Reduction. DEFINE Six Sigma Project Team: Black-Belt:Jim Altier Green Belt Candidates: Project Sponsor: Project Champions(s):

Downtime Reduction Downtime Reduction Project: Downtime ReductionDate Opened: October 30, 200xI&CIM Contact: Jim Altier

Customer: UsersProject Sponsor: SuperintendentProject status: Control and Maintain

Problem Definition

•Department, Area, 30% of all maintenance downtime due to process related calls.• Print requirement for process is: “Present on the mating interface area and on the outside of the core crimp wings”.

Project Scope• Reduction in process calls and faults due to an inconsistent process.• Goal is an 80% reduction in faults and calls as well as associatedscrap generated by start stop and 25% reduction in overtime.

Implement Improvements

Control and Maintain

Characterize Current State/ID failure modesCurrent State: •process is applied to the parts via Central Lube System, pressurized source. The oil is applied post stamping process andpre-reeling.• A presence detection system that verifies the presence of oil in the contact areas of each terminal type (male / female), is in place.• 40% of maintenance calls due to process (70% PF & 24% EL).Failure modes:• Inconsistent sensing at the current levels of process application. • Process capability currently at .8708 Cpk & 2.6 Sigma.

• All presses changed to reflect the values determined by experimentation during the project.• Engineering developed a troubleshooting guide for thetrades, supervisors, technicians and operators in determine settingsand changes in the process during operation.

• Based on data from the SEM the low level of process was changed from 250 units to 150.

• Gage R&R performed on the sensor, the sensor is capable of distinguishing various levels of process from part to part.

• Capability was improved to 4.1 Sigma from 2.6 and Cpk to 1.39 from .8708.

• process related downtime (hours) has been reduced from an average 638 hrs. a month to 212, a 68% improvement, faults were 8.4% of the total, now 2.6%, a 69% improvement. Start/Stop scrap reduced by 69%, a $17,000.00 savings, process related maintenance calls were 30% of all calls, now 12% , a 60% improvement.

Sigma Level = 2.6123USL = 650 / LSL = 250

Cpk = .8708DPM = 4,510

Faults

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Jun-02 Jul-02 Aug-02 Sep-02 Oct-02 Nov-02

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# of

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USL = 650 / LSL = 150Sigma Level = 4.1903

Cpk = 1.3968DPM = 22.0

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74% reduction

Changes made to machine logic regarding high & low fault points (3/21/03)

SEM Analysis

Evidence that process is present at low reading.

Pipe fitter calls have reduced gradually since the beginning of the project. Partially due to the attention placed on the problem and education during the improvement phase.

Downtime Reduction Downtime Reduction D

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Six Sigma Project Team:Black-Belt: Jim AltierGreen BeltCandidates:

Project Sponsor:Project Champions(s):Master Black-Belt:

Problem Statement and BackgroundPlant X, department x currently produces the GT Terminal family, the terminal print requires a presence of process onall parts. process is a silicone fluid used to enhance the conductivity of the connection. A by-product of process is that it aids in crimping, therefore, it is required on the back side of the core crimp wings. The print defines the amount of process with a spray rate of .75 gallons per million parts and present in the mating interface and on the outside of the core crimp wings.

process is supplied by vendor at a cost of $355.00 per gallon. vendor does not produce the silicone fluid, they merely mix a UVtracer in and distribute. The tracer is used for sensing only.

Current process application and sensing process accounts for 30% of all maintenance downtime in Plant X, department x.The process is post stamping and applied via a pressurized source with a reclaim system for the excess fluid. The sensingequipment works entirely off of the UV tracer through a sensor. This instrument is used to detect the luminescent properties of the process material. The visible light is received and converted to an analog signal that is tiedto the stamping press. If the process level falls below or above the preset limits of the sensor the press will fault out and shutdown. Various terminal parts numbers are start stop sensitive and generate scrap reels every time the press shutsdown. At this time the data from the sensor is averaged every 225 readings and compared to the preset limits, whichare 250 to 650. Once 6 consecutive readings fall out of the range the press faults and shuts down.

process related downtime is equivalent to 1 hour down time for every 8 hours of run time. The goal of the project team is toreduce downtime and related scrap by 80%. An 80% reduction will increase capacity by 1,000,000 parts. The increased capacity will be used to reduce overtime by 25% which is worth $40,000.00 and a scrap savings of $20,000.00.

Downtime Reduction Downtime Reduction

Nyosil All Nyosil All Nyosil AllNov-02 38 89 35 115 21 109Oct-02 38 132 67 196 43 153Sep-02 39 125 66 183 35 132Aug-02 18 166 46 170 36 161Jul-02 8 94 23 114 28 115Jun-02 8 194 23 114 28 115Total 149 800 260 892 191 785Avg. 25 133 43 149 32 131

% due to Nyosil

80% reduction inNyosil Calls

MonthlyWeeklyDaily

19% 29% 24%

29.8 52 38.2

24% of all electrician calls are due to Nyosil

EL CallsAM PM MN

0.25 0.43 0.32

5 9 61 2 2

Nyosil All Nyosil All Nyosil AllNov-02 31 51 44 52 28 40Oct-02 53 74 67 89 43 56Sep-02 85 116 109 142 48 69Aug-02 59 87 72 109 52 75Jul-02 23 48 22 48 36 58Jun-02 36 49 40 55 50 56Total 287 425 354 495 257 354Avg. 48 71 59 83 43 59

% due to Nyosil

80% reduction inNyosil Calls

MonthlyWeeklyDaily

AM PM MNPF Calls

68% 72% 73%70% of all pipefitter calls are due to Nyosil

51.4

30.59

57.4 70.8

92

0.43

102

0.48

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Data collected from the maintenance dispatch system.

Total Calls = 807Total Work Time = 759

Total Response Time = 1,156 Total Downtime = 1,915

Peroid of 8/1 thru 10/24/02Calls Work Hrs Response Hrs

Low Nyosil / Nyosil Low 177 158.06 241.86High Nyosil/Nyosil High 152 162.21 201.82Calibrate sensor 75 63.24 67.96Other / misc / not enough info 73 68.36 104.39Dispense Tank faults 71 51.83 224.38sensor/sensor faults 57 39.24 61.16Nyosil Block 44 56.79 72.7low level /level low 41 21.7 41.79adjust (~75% sensor related) 35 33.73 37.26missing inspections 22 8.94 21.92changeover/ change-over/c/o 19 50.22 28.77Too much Nyosil 15 14.17 14.64leak 14 14.86 23.56reclaim tank 9 12.67 12.46spill 3 2.98 1.33

Total Faults = 807 759 1156Total w/out undefined = 734 690.64 1051.61

Sensor Related Calls / % to total = 550.25 75.0%Sensor Related Work Hrs / % to total = 478.7 69.3%Sensor Related Resp Hrs / % to total = 664.5 63.2%

Downtime Reduction Downtime Reduction D

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Pareto Chart

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Cpk Analysis

139

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In spec

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LSL

USL

Short Term

Short TermMean = 403.608StdDev = 53.848USL = 650LSL = 250Sigma Level = 2.8526Sigma Capability = 3.7142Cpk = .9509Cp = 1.2381DPM = 2,170N = 209

Long TermMean = 403.608StdDev = 58.801USL = 650LSL = 250Sigma Level = 2.6123Sigma Capability = 3.4013Cpk = .8708Cp = 1.1338DPM = 4,510N = 209

Prior to Improvements

Downtime Reduction Downtime Reduction I

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Cpk Analysis

139

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210

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In spec

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LSL

USL

Short Term

Short TermMean = 403.608StdDev = 53.848USL = 650LSL = 150Sigma Level = 4.5757Sigma Capability = 4.6427Cpk = 1.5252Cp = 1.5476DPM = 3.613N = 209

Long TermMean = 403.608StdDev = 58.801USL = 650LSL = 150Sigma Level = 4.1903Sigma Capability = 4.2517Cpk = 1.3968Cp = 1.4172DPM = 22.0N = 209

After Improvements


Electrician

0153045607590

105120135150165


# of

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58% reduction in electrician calls

IM

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Pipefitter Calls

0255075

100125150175200225250275300325350


# of

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74% reduction in pipefitter calls


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Downtime Reduction Downtime Reduction C

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Process Settings Program set points: Nyosil Fluid Pressure 7 psi Nyosil level set point 400 Vacuum Air 20 psi Nyosil low level warning 200 Dispense Tank Air 20 psi Nyosil low level fault 150 Reclaim Tank Air 40 psi Nyosil high level warning 600 After Actuating Manual Pneumatic Valve Nyosil high level fault 650 Actuation Air >70 psi Atomizing Air 5-10 psi

Process Settings Program set points: Nyosil Fluid Pressure 7 psi Nyosil level set point 400 Vacuum Air 20 psi Nyosil low level warning 200 Dispense Tank Air 20 psi Nyosil low level fault 150 Reclaim Tank Air 40 psi Nyosil high level warning 600 After Actuating Manual Pneumatic Valve Nyosil high level fault 650 Actuation Air >70 psi Atomizing Air 5-10 psi

Pulsar Presses

Aida Presses


Mean = 403.608 / StdDev = 58.801USL = 650 / LSL = 150

Sigma Level = 4.1903 / Sigma Capability = 4.2517Cpk = 1.3968 / Cp = 1.4172

DPM = 22.0 / N = 209

Documents

Downtime Reduction Downtime Reduction. DEFINE Six Sigma Project Team: Black-Belt:Jim Altier Green Belt Candidates: Project Sponsor: Project Champions(s):