LSS Yellow Belt Project

Yellow Belt Project Tony Ponsonby

© Landis+Gyr | 8 March 2015 | INTERNAL

Cup Yield Increase From Syntactic Foam Rods

2Tony Ponsonby | © Landis+Gyr | 8 March 2015 | INTERNAL

Define

Introduction

Syntactic foam rods are produced at BL Gas as a raw material and used in production

of ultrasonic transducers. After the rod has been moulded, they are sawn to length,

final baked weighed, batched and processed on a CNC lathe to produce the

transducer cup.

Currently 13 cups are machined from each 150mm long rod. This equates to 69.3 %

(104mm) Value with 30.7% (46mm) Scrap.


Define

Voice of the Customer

Phil Smith – “We require 8k transducers per day going into March / Twilight shift”

Craig Marsden – “L+G can’t produce enough meters to meet customer demand”.

For every additional meter made there is a margin contribution of £33.

Tony Ponsonby – In order to meet increasing demand, I want to focus on waste

reduction to yield a higher output from the same input quantity instead of

processing more inputs to produce a greater output.


Define

SIPOC

Rod Room

Syntactic Foam Rods (600 Max

/ Day)

CNC Machining of

Cups

Machined Cups (Max 7800 /

Day)

Transducer Room

Rod Weight 12.5 – 13.5g15mm Diameter

Flat/Square sawn endsBatched Correctly

Correct DimensionsBatch Correctly


Define

Problem Definition• 30.7% of rod room production effort is wasted

• Existing cup output can only be boosted by increasing the number of rods made each day. (These are not available from another source)

• No up-to-date SOP’s are in place. The active method from 2007 relate to a machine that is no longer used.

• Single Point of Failure - Only 2 persons (1 technician /shift) are able to operate the machines to a level required to consistently maintain cup production.

• Rod weights 12.5 -13.5grams as specified by the MPT were not being used correctly by FRS resulting in rods weighing 12-13grams being accepted. This lead to good rods being rejected http://data.uk.bm.net/redmine/issues/3904

http://data.uk.bm.net/redmine/issues/3904

http://data.uk.bm.net/redmine/issues/3904


Define

Objectives

S - To produce an extra transducer cup / rod focusing by on processing wastes within each rod

M - To reduce rod waste from 30.7% to 25.3% by producing an additional cup /rod

A - Waste can be reduced through

1. Eliminating Waste i.e. work-piece overhang

2. Reducing Necessary Waste i.e. the amount removed in machining operations

R - An initial review meeting with Simon CNC services has shown this reduction possible

T - This project will be completed within 8-12 weeks


Define Project Benefits 1. Increase cup production by 7.69% for the same amount of raw material

2. Facilitate an additional 600 Txr’s / day or (108k Meters /Annum)

3. Increase maximum cup yield from 7800 to 8400 / day

4. Reduce rod room burden (Muri) to produce more rods with increasing customer demand

5. Sustained Production

I. Eliminating Single-Point-Failures – (Initial Training)

II. Increased Engineering knowledge

III. Standard work – SOP’s created

IV. Succession Planning – SOP’s allow future operators to be trained against tangible requirements6. Overheads associated with Rod & CNC manufacture can be apportioned over a larger output, effectively

reducing the cost per cup by £0.007

7. If 600-off additional cups are used in meter production, the contribution to margin = £9.5k/day (£3.37m/Yr.) – P Timmis


Define Stakeholder Analysis Tony Ponsonby – Project Leader

Daniel Holtby – Project Sponsor

L+G - Spinner CNC Trainees

TP/PB/JC/VN/AL L+G Team Leaders / Shift managers

Simon CNC Services for technical support

Resources Required £2.6k - CNC training fee(Authorised)

£920 for initial CNC 14th cup machining trial (Authorised)

£5k Contingency (£685 Spent)

Total cost £4205

Project Influence

Project Availability

High

High

Low

Low

Dan Holtby

Tony Ponsonby

L+G Operators

Simon CNC

Maintenance

L+G Cell Leader

Txr Metrology

Youra T

Pete H

Manufacturing Engineering

SMT

Rob McNamme

Seco RFC Signatories

R+D

Primary Stakeholders


Define DMAIC Project Plan

ID Task Name March 2015 April 2015 May 201527 02 05 08 11 14 17 20 23 26 29 01 04 07 10 13 16 19 22 25 28 01 04 07 10 13 16 19

1 Define2 Introduction3 VOC4 SIPOC5 Objectives6 Benefits7 Stakeholder Analysis8 Measure & Analyse9 Rod Capability

10 13-Cup Cycle-Time / Value11 13-Cup Weight12 Improve13 CNC Trial14 13-Cup Cycle-Time / Value15 14-Cup Weight & Capability16 CNC Training17 RFC18 Control19 SOP Creation20 Training Sign-Off21 Complete DMAIC

Project: 14th Cup Gantt ChartDate: Wed 13/05/15

Task External Milestone Manual Summary Rollup

Split Inactive Task Manual Summary

Milestone Inactive Milestone Start-only

Summary Inactive Summary Finish-only

Project Summary Manual Task Deadline

External Tasks Duration-only Progress

Page 1


Measure & Analyse

Rod / Cup Material Costs

Part Number Description Mass (mg) £ / kg of material £ / Cup17510-30100 RESIN CY228 1865.58 15.32 0.0286 17510-30101 RESIN HARDENER HY918 1232 13.578 0.0167 17510-30102 RESIN ACCELERATOR DY062 4 62.38 0.0002 17510-30200 RESIN SILAN A 186 14.08 81.5 0.0011 17510-63400 AIR RELEASE AGENT 26.08 24.22 0.0006 P000227170 FTD200 Ecospheres 888 65.77 0.0584

£ / 2 Cups 0.106£ Production Days £ / Cups 0.053£

3656 xmas (Planned shut down)3 Sep (Planned shut down)3 mar (Planned shut down) Number of rods / day 600

(Ref: Project Unite)353 Days operating Material Cost/Rod 0.687£

Material Cost/Year 145,573.96£ Courtesy of P Timmis

Rod Material Cost / Tube Assembly (on Consumegas 12 BOM)

Part Number Description kg / 12 months £/kg £/12Months17510-30100 RESIN CY228 1965 11.14 21,890.10£ 17510-30101 RESIN HARDENER HY918 1525 13.58 20,709.50£ 17510-30102 RESIN ACCELERATOR DY062 6 62.37 349.27£ 17510-30200 RESIN SILAN A 186 18 81.5 1,467.00£ 17520-63400 AIR RELEASE AGENT 25 24.22 605.50£ P000227170 FTD200 Ecospheres 1852 65.77 121,827.09£ Courtesy of S Stennings 5391 166,848.46£

Actual Rod Material Consumption in past 12-months

Actual usage found to check BOM costs - could be higher due to inventory stocks

BOM costs based on 353 day / Yr operations & 600 rods per day


Measure & AnalyseLabour Cost

Material + Labour Cost

Annual Cost Days operating cost per dayDirect Head £20,900 353 £59.21Rod Room 2 head (x 2 shifts) £83,600 353 £236.83CNC 1 head (x 2 shifts) £41,800 353 £118.41Courtesy of P Timmis £125,400 £355.24

Courtesy of P Timmis13 cups 14 cups Tx Production per annum 2,965,200

Qty Produced 7800 8400Labour Cost / Day 355.24£ 355.24£ Scrappage saving Value per Cup 0.0070£

Material Cost / Day 412.39£ 412.39£ Cost per Cup (Cost / Qty ) 0.0984£ 0.0914£ Value of waste removed from process 20,844.15£

Cost Per cup - day

Payback

Project cost = £4205

Payback = < 3 months


Measure & Analyse14th Cup Contribution to Margin

Courtesy of P Timmis13 cups 14 cups

Produced per day (Qty) 7800 8400Days operating 353 353Annual Production (Qty) 2,753,400 2,965,200

Additional cups produced from same material 211,800No other Bottlenecks would allow another 108,900 meters to build 108,900 (2 x cups per meter )

Perfect Scenario Sales would be able to generate additional i.e. G370 @ £66.00 7,187,400.00£

G370 CM @ 46.9% 3,370,890.60£

Annual Simulation

Allows L+G to make this many more meters / Year

Allows L+G to make this additional profit


Project Risk

Risk Likelihood

High

High

Low

Low

Insufficient trained L+G Operators Operators

Insufficient CNC

Knowledge

Other Business Requirements

RFC

Rejection

Project Completion

Project Continuity

Insufficient CNC

Technical Support

No SOP’s

Simon CNC not available

Tool design can’t be changed

Additional Material can’t

be attained

High cup demand

Too high 14th Cup weight

Too high 14th Cup weight

Adverse dimensions

Poor OEE

Measure & AnalyseRisk Matrix

Identify all project risks

Risk to project completion

Risk to project continuity

Eliminate / Reduce the risk (low

risk / low likelihood)


Measure & AnalyseHistorical Rod Weight Capability

cUPAchieve 14th

Environment

Measurements

Methods

Material

Machines

Man

Cup Yield Increase From Syntactic Foam Rods

Non uniform rod weight

No SOP’s

No Technical Support

Too much material wasted on overhang

Too much material wasted on face-off

Too much material wasted on part-off

No formal training

No formal training

Cup weight

Temperature

Fixture bias

Rod length variation

Minimum grip length

Machine capability

Rod loading orientation

Tool Life

External Support

Transducer Specification

Lack of Tooling

Myths

Culture

Resistance to Change

Stories


Measure & AnalyseRod Weight Capability

Rod Weight Capability after the

introduction of the new rod cutter on 6th

March 2015

• 520 samples taken since introduction

• Target 13g – Actual 12.97g

• Zero DMPO

select * from tr2where date(date) > '2015-03-06‘order by date desc;


Measure & Analyse

13 Cups Per Rod Cycle-Time

The existing CNC process was video recorded and analysed to

quantify the Cycle-Time per Rod and Per Cup.

This was further broken down

• Value-Adding times per rod

• Necessary Waste times per rod

Of the Total Processing Time approximately 35% is attributed to Necessary Waste. This potentially could be reduced as part of this project.

Assuming 100% OEE, A maximum of 2206-off cups could be produced per 12-hour shift per machine. (8824-off per 4 CNC’c)

This means the existing OEE is 88.39% when producing 7800cups/day from 600 rods

In order to machine the 14th Cup and produce 8400 cups per 600 rods. The OEE would need to be 95.19% (assuming the cycle-time remains the same)

165.1

12.7

87.8

6.75

0

20

40

60

80

100

120

140

160

180

200

220

240

260

Rod Cycle-Time (S) Cup Cycle-Time (S)

Tim

e (s

)

Machining Time To Produce 13cups

NecessaryWaste TimePer rod (s)

Value TimePer rod (s)


Measure & Analyse

13 Cups Per Rod Proportions

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

1

2Cups 104 mm

Part Off 16.9mm

Saw Scrap 14.95mm

Material Overhang 7.35mm

Materialin Chuck5.5mm

Facing-Off,1.3mm

Rod Length mm)

Rod Value to Produce 13 Cups


Measure & AnalyseFixture Bias VS Internal Rod Mass

It has been found that the rod density is not uniform throughout the length of the rod. The cause of this is due to the orientation of the rod within the rod moulding fixture.

The chart below shows the characteristic cup weight within the rod vs rod orientation within the mould fixture. With 150mm long rods – it can be seen the cup mass dips approx 30mm up from the base. This could be due to the asymmetry of the mould but is not proven within this project.

0.37

0.38

0.39

0.4

0.41

0.42

0.43

0.44

0.45

Cup Weight (g)

mm fromleading rod face

Characteristic Cup Weight based on Rod Orientation

AverageWeight (Baseof rod fixtureat leadingface)

AverageWeight (Topof rod fixtureat leadingface)

Top Of Rod Fixture

Base Of Rod Fixture

Rod Fixture Lid


Measure & AnalyseMass Of Cup At Each Position Within The Rod

20 rods have been machined as normal in the CNC lathe, with rods normally get loaded into the lathe arbitrarily

The Process Expert has marked the position (1-13) of every cup within the rod, and the mass of each cup has been recorded.

The graph opposite shows the cup mass at each position across 20-off rods.

It can be seen that there are 2 distinct profiles as indicated in previous slide

The Graph below right shows the capability analysis of the measured cup weights. Whilst no defect were found it is expected that the DPMO is 2368 for 13 Cup / Rod based on a cup weight of 0.37-0.46mg tolerance

0.4

0.41

0.42

0.43

0.44

0.45

0.46

1 2 3 4 5 6 7 8 9 10 11 12 13

Cup

Mas

s (g)

Position of Cup

Mass of Cup At Each Position Within The Rod Rod ARod BRod CRod DRod FRod GRod HRod IRod JRod KRod LRod MRod NRod ORod PRod QRod RRod SRod T


Improve

14 Cups Per Rod Cycle-Time

Reduced the Cup cycle-time by 0.93 Seconds per cup this equates to a 4.8% reduction in the cycle-time

Reduced Cycle time from 19.58s down to 18.65s per cup

Time per rod = 261.13 seconds for 14 cups compared to 254.6 Seconds for 13 cups

Non-Value Added Time reduced from 35% down to 25.9%

13-Cup OEE is 88.39% when producing 7800cups/day

14-Cup OEE is 90.66% when producing 8400cups/day

Additional OEE performance gained by re-scheduling CNC shut-down sequence.

193.4

13.81428571

67.73

6.75

0

20

40

60

80

100

120

140

160

180

200

220

240

260

Rod Cycle-Time (S) Cup Cycle-Time (S)

Tim

e (s

)

Machining Time To Produce 14cups

NecessaryWaste TimePer rod (s)

Value TimePer rod (s)


Improve14 Cups Per Rod Proportions

Increased the value of rod from 104mm to 112mm Reduced waste from 46mm to 38mm – (17.3% reduction in rod waste) Reduced physical waste per year by 82.4kg (based on 350 manufacturing days at 8400 cups per day with each cup being .42g avg)

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

13thCup

14thCup

104mm

112mm

16.9mm

18.2mm

14.95mm

11.55mm

7.35mm

1.35mm

5.5mm

5.5mm

1.3mm

1.4mm

Rod Length mm

13 to 14 Cup Comparision

Cups Part-Off Saw Scrap Material Overhang Material in Chuck Facing-Off


ImproveCup Weight for 14 Cups / Rod

20 rods have been machined as normal in the CNC lathe, with rods normally get loaded into the lathe arbitrarily

The Process Expert has marked the position (1-13) of every cup within the rod, and the mass of all 280 cup has been recorded.

The graph opposite shows the cup mass at each position across 20-off rods.

It can be seen that there are 2 distinct profiles as shown previously

0 Defects found

0.37

0.38

0.39

0.4

0.41

0.42

0.43

0.44

0.45

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Cup Weight (g)

Cup Positionin Rod

Txr Cup Weight Vs Position in Rod

Rod 5 Rod 7 Rod 11 Rod 12 Rod 13 Rod 16 Rod 17Rod 2 Rod 4 Rod 6 Rod 8 Rod 9 Rod 10 Rod 14Rod 15 Rod 18 Rod 19 Rod 20 Upper Limit Lower Limit


ImproveMass Of Cup At Each Position Within The Rod

The plot to the right shows the capability analysis of all 280 cup

weights. It can be seen that the whilst 0 DPMO was recorded,

Minitab predicts that 261 DPMO is expected based upon the

distribution of results found

Total N 278Subgroup size 20Mean 0.41987Standard deviation (overall) 0.0086844Standard deviation (within) 0.0080215

Process Characterization

Cp 1.66 Cpk 1.25 Z.Bench 3.76 % Out of spec (expected) 0.01 PPM (DPMO) (expected) 86

Actual (overall) Pp 1.54 Ppk 1.16 Z.Bench 3.47 % Out of spec (observed) 0.00 % Out of spec (expected) 0.03 PPM (DPMO) (observed) 0 PPM (DPMO) (expected) 261Potential (within)

Capability Statistics

0.45000.43750.42500.41250.40000.38750.3750

LSL Target USL

Capability HistogramAre the data inside the limits and close to the target?

Actual (overall) capability is what the customer experiences.

process shifts and drifts were eliminated.Potential (within) capability is what could be achieved if

Capability Analysis for 14 Cups Per RodProcess Performance Report

Total N 258Subgroup size 20Mean 0.41952Standard deviation (overall) 0.0087895Standard deviation (within) 0.0081841

Process Characterization

Cp 1.63 Cpk 1.24 Z.Bench 3.72 % Out of spec (expected) 0.01 PPM (DPMO) (expected) 98

Actual (overall) Pp 1.52 Ppk 1.16 Z.Bench 3.47 % Out of spec (observed) 0.00 % Out of spec (expected) 0.03 PPM (DPMO) (observed) 0 PPM (DPMO) (expected) 262Potential (within)

Capability Statistics

0.45000.43750.42500.41250.40000.38750.3750

LSL Target USL

Capability HistogramAre the data inside the limits and close to the target?

Actual (overall) capability is what the customer experiences.

process shifts and drifts were eliminated.Potential (within) capability is what could be achieved if

Capability Analysis for Cups 1-13.Process Performance Report

The plot to the left shows the capability analysis of cup positions 1-13 (258 cup

weights). It can be seen that the whilst 0 DPMO was recorded, Minitab predicts

that 262 DPMO is expected based upon the distribution of results found.

Conclusion – The additional cup does not negatively affect the DPMO


ImproveRequest For Change

• L+G RFC025554 raised 29/4/15

• Report – Increased transducer

cup yield submitted with the

RFC in support

• RFC approved & ECO released

12/5/15


ImproveReduced Work-Piece Overhang

The work piece overhang (Z) in the CNC has been reduced by

6mm to achieve the additional cup. As such the deflection has

reduced by 0.05mm when machining the 1st Cup of every bar-

feed. This can be seen when viewing the CNC X axis datum offset

(G54 Fanuc code) of the main cup program.

Whilst no data is available yet, it is suspected that reducing the

deflection of this cantilever will:

Reduce tool wear

Increase tool life

Reduce dimensional variation from Cup 1 to Cup 2 of each bar

feed. Cup2 Cup 1

Bar Deflection


Press to Stop

Air to operate and flag a error

STF070 - Method Sheet Template / Feb 2014 / Issue 3 Document Classification: Internal

PAGE 1 OF 4

Mgr Quality Eng Eng TL Date ofIssue

22/04/2015 Issuer T PonsonbyDB RM TP DK/JR Revision No. & Reason

Approved by Date Revised by

Job Name CNC Start-Up Operations Line Transducer Assembly Rev 1 New method sheet SF 22.4.15 TP

Q-Pulse No. STMS329 OP

№ Op100COSHH REF STCoSHH18,19 MHV Time

RISK ASSESSMENT REF STRA165 STPUW ER043,040,023

1 2 3

Switch the Isolater on Switch the light on Release the E-Stop

Light On/Off E-Stop

Turn CW toIsolator On/Off Release

4 5 6

Turn the Compressed Air On Turn the Vacuum System On View the machinealarms

Air On/Off

6 Bar Approx

Off On MC

Materials & Equipment PPECNC Machine Mandatory PPE must be worn at all timesVacuum extraction machine Safety goggles to be worn at all timesBatches of 139mm long rods inc Bar Codes Disposable organic vapour face mask (FFP2) to BS EN 149 to be worn when accessing machines orCNC production log cleaningContainersScrapper15mm Collet Special Precautions

Do not mix batches of rods across CNC'sKeep the cups in the same batch after machiningRefer to corresponding method sheet for tool set-up / Dimension Checks / Routine Maintenance /Shut-Down

Work Steps Symbol Result, Safety, and Workability If not followed

1 Switch the Isolater on The Fanuc program will load Delays

2 Switch the light on After the Fanuc program has loaded - Press the light buttonThe light to the inside of the CNC will turn on Difficult to see inside the CNC

3 Release the E-Stop Turn the E-Stop CW Delays

4 Turn the Compressed Air On Turn the Valve onThe pressure gauge will go to 6 bar

The Machine will not have any Compressed

5 Turn the Vacuum System On Press the green 'start' button on the vacuum systemThe Vacuum will sound Swarf will not get removed from the machine

6 View the machine alarms Press the MC Alarm button Uncertaintly of what Errors are present

Safety or M.S.S Quality Point Knack/sensitivity point e Environmental pointSymbols

Revision (See detail in revision box)

ControlSOP Creation

1. STMS329 - CNC Start-Up

Operation

2. STMS333 – Cup Dimension

Check & CNC tool offset

3. STMS330 – CNC Shut Down

Operation

4. Training Records created /

signed and issued

Auto


PAGE 2 OF 4







RISK ASSESSMENT REF STRA165 STPUWER043,040,023

7 8 9

Press Reset Open & Close the door to remove door alarm Execute 'Safe Test'

Reset

Safe Test

10 11 12

Press Auto button View & reset the NC errors Check Variable #516 is Zero (A)

Reset

NC Error Offset

Materials & Equipment PPECNC Machine Mandatory PPE must be worn at all timesVacuum extraction machine Safety goggles to be worn at all timesBatches of 139mm long rods ink Bar Codes Disposable organic vapour face mask (FFP2) to BS EN 149 to be worn when accessing machines orCNC production log cleaningContainersScrapper15mm Collet Special Precautions



7 Press Reset

The following alarms should clearAir pressure missing Circuit breaker triggered Pressure at main spindle Peripheral circuit breaker E-Stop activated

Errors won't be cleared

8 Open & Close the door to remove door alarm

Slide the CNC door right then left to closeThe door alarm should clear Errors won't be cleared

9 Execute 'Safe Test' Press & hold the Execute button until you hear the machine'click' until the test is complete Machine will not run

10 Press Auto button Press the Auto button to allow the CNC program to run Machine will not run

11 View & reset the NC errorsPress the NC error button to view the remaining alarmsPress the reset button to clear remaining alarms Errors won't be cleared

12 Check Variable #516 is Zero (A)This ensures the CNC will machine cup 1 firstPress the Offset button Unknown start point / Collision



Page Up

18

Zero KeyLook here for

+ Button

Edit Protect Key

Check the are no burs on the rodsCupboard

The CNC will not operate if the door is open

If burrs are found - Remove them with a scrapper


PAGE 3 OF 4








13 14 15

Check Variable #516 is Zero (B) Check Variable #516 is Zero (C) If it is not Zero #516

516 should be yellow

516 Input Key

Cursor Keys

Page Up

Page Down

Macro

16 17

Check there are rods in the hopper If the Hopper is empty - Get more rods from




13 Check Variable #516 is Zero (B) Press the + Button Unknown start point / Collision

14 Check Variable #516 is Zero (C) Press Macro ButtonPress the Page UP / Page Down button to locate variable #516 Unknown start point / Collision

15 If it is not Zero #516

Cursor to #516 - 516 will highlight yellowTurn the Protect Key OffKey in Zero (0) Press 'Input'Turn the Protect Key On

Unknown start point / Collision

16 Check there are rods in the hopper Look inside the hopper to check there are rodsClose the lid if you open the hopper

The CNC will flag an error if no rods are present

17 If the Hopper is empty - Get more rods from Cupboard

Open cupboard and select a box of rodsBlue Box - CNC B Green Box - CNC C Yellow Box - CNC D Red Box - CNC E

Confusion to normal process

18 Check the are no burs on the rods Slide all rods from the batch through the spare 15mm collet Rods will stick in the bar feeder



The CNC will not operate if the door is open


PAGE 4 OF 4








19 20 21

Complete CNC production log Fill the hopper Store the empty rod box

22 23 24

Press the Cycle-Start button Machine the Cups 0

Cycle Start Button




19 Complete CNC production log Stick the spare rod bar code onto the CNC production log onto the relevant CNC the rods will be machined Confusion to normal process / Traceability Issues

20 Fill the hopper

Open the hopper lidPlace the full batch of rods into the empty hopperClose the hopper lid

The CNC will flag an error if no rods are present

21 Store the empty rod box Place the empty Rod box on top of the CNC This is ready to collect the cups Confusion to normal process / Traceability Issues

22 Press the Cycle-Start button The machine will eject the last rod end and loadAfter the rod has loaded the CNC will start to turn cups Delays

23 Machine the Cups Take Cup Dimension check for each CNC every 2 hours using the relevant method sheet Delays / Quality Issues

24



Prepare to collect cups Collect Cup 1 and Cup 2stop

Select TR1 Program Run TR1 Programother CNC's

Other CNC cups not measured

Wrong FRS program selection


PAGE 1 OF 7


12/05/2015 Issuer T PonsonbySF RM TP Revision No. & Reason


Job Name Cup Dimension Check & CNC Tool Offset Line Transducer Assembly Rev 1 New method sheet SF 12.5.15 TP




1 2 3

Wait for the CNC to push the rod out to the end-

Cup 2 Cup 1

Cup Tray

4 5 6

Reinstate the CNC and Collect Cups from

Materials & Equipment PPECNC Machine Mandatory PPE must be worn at all timesMitutoyo Digimatic Indicator Safety goggles to be worn at all timesFRS Linked PC Disposable organic vapour face mask (FFP2) to BS EN 149 to be worn when accessing machines orGO-NOGO gauges cleaningCup dimension drawingCup Tray Special PrecautionsGround steel block Keep cups from each CNC separate when taking measurementsMagnification Eye Glass - RS 544-055 Use the Cup tray to ensure Cup1 or Cup 2 from each machine do not get mixedCup drawing - D000042602A Take cup dimensions from each CNC every 2 hours


1 Wait for the CNC to push the rod out to the end-stop

The rod will push out to the end stop - you will hear a blastof compressed air as the rod moves Confusion

2 Prepare to collect cupsPull the drawer openMove the cup bin (full of cups) from under the chutePlace an empty bin under the chute

Delays

3 Collect Cup 1 and Cup 2

Wait for Cup 1 to drop down the chute and place into the relevant Cup Tray positionWait for Cup 2 to drop down the chute and place into the relevant Cup Tray position

Corrupted cup measurement

4Reinstate the CNC and CollectCups from other CNC's

Move the cup bin (full of cups) back under the chuteClose the collector drawerCollect cups using the same process from the other CNC's

CNC's not reinstated - H&S trip / dust hazard

5 Select TR1 ProgramTake all cups to the FRS PCSelect TR1 - Ceramic Cup DimensionPress Enter

Delays

6 Run TR1 Program Press 1 then Enter to progressPress 2 to return the main menu Delays



Mismatched dimensions - possible scrap



STF070- MethodSheet Template/ Feb 2014 / Issue3 DocumentClassification: Internal

PAGE 2 OF 7


12/05/2015 Issuer T PonsonbySF RM TP

Revision No. & Reason Approved by Date Revised by


Q-Pulse No. STMS333

OP№ Op110

COSHH REF STCoSHH18,19 MHV Time


7 8 9Log into the TR1 program Select the Date Scan the Batch Barcode

10 11 12

Key in the CNC Letter Check the Batch No Remove the Cups part-off Pip



7 Log into the TR1 program Key in your Operator FRS ID Press Enter Incorrect ID / Delays

8 Select the Date Press Enter to select todays Dateor key in a specific date and press enter Incorrect Date

9 Scan the Batch Barcode

For each CNC - Scan the batch barcode on the production log which the cup relates toAim the scanner at the barcode and press the scan buttonIf the scanner does not scan - key in manually

Incorrect Barcode/Batch number

10 Key in the CNC LetterKey in the CNC Letter (either B,C,D,E) where the cup was machinedPress Enter


11 Check the Batch No

Check that the Batch No on the FRS screen matches theBatch No on the production logIf the numbers don't match - Press escape, re-start the program and re-enter


12 Remove the Cups part-off PipRemove the pip on the front face of the cup by sliding over the ground steel block. Remove any dust swarf using the blowgun

Incorrect measurements - Possible Scrap



progress into Transducer manufacture

Inaccurate recording - possible scrap



PAGE 3 OF 7





Q-Pulse No. STMS333

OP№ Op110



13 14 15

Zero the Indicator Measure & Record Cup 1 Dimensions Measure Cup1 OuterDiameter

Zero On /Off

Stylus should touch the base

16 17 18

Key in the Diameter into FRS Measure Cup1 Height & record Measure Cup1 Floor Height & record



13 Zero the IndicatorEnsure the stylus is touching the steel baseSwitch the indicator onPress the Zero button - the display will Zero

Untrue reading - Possible scrap

14 Measure & Record Cup 1Dimensions

Measure & Record Cup Dimensions as per Steps 15-24If any dimension is close to the limit- Re-target the CNC offset using work steps 30-41If the dimension is out of limits- Re-target the CNC offset using work steps 30-41- Inform your cell leader- Scrap all cups produced on the machine since the last cup check

Out-Of-Tolerance Cups are allowed to

15 Measure Cup1 Outer DiameterPlace the cup diameter under the stylusRotate the cup & measure the largest diameterCheck that the diameter is between 14.095-14.135mm

Inaccurate measurement - possible scrap

16 Key in the Diameter into FRS Ensure the Outside Diameter is selected (will highlight Yellow) Key in the Diameter


17 Measure Cup1 Height & record

Place the cup under the stylusMeasure the cup heightCheck that the height is between 7.95 - 8.05mmkey in the measurement as per step 16


18 Measure Cup1 Floor Height &record

Place the cup under the stylusMeasure the cup Floor HeightCheck that the height is between 3.975 - 4mmkey in the measurement as per step 16




Measure Cup1 Step Height & record Gauge Check Cup1 Ø3 hole & recordHeight & record

Undercut & record







Symbols


PAGE 4 OF 7


12/05/2015 Issuer T PonsonbySF RM TP Revision No. & Reason Approvedby Date Revisedby


Q-PulseNo. STMS333

OP№ Op110



19 20 21

Measure Cup1 3mm Hole Depth to Floor

22 23 24

Gauge Check Cup1 Inside hole & record Gauge Check Cup1 Step Diameter & record Visually Inspect Cup1 Chamfer + Radii +



19Measure Cup1 3mm Hole Depth to Floor Height & record

Place the cup under the stylusZero the indicator on the depth of the Ø10.1 Recess faceMeasure the Recess face to 3mm hole depth Check that the height is between 0.5-0.55mm key in the measurement as per step 16


20 Measure Cup1 Step Height &record

Place the cup under the stylusZero the indicator on the depth of the Ø10.1 Recess faceMeasure the Ø10.1 Recess to Ø11 bore Check that the height is between 0.5-0.6mm key in the measurement as per step 16


21 Gauge Check Cup1 Ø3 hole &record

Check Cup1 Ø3 hole using the 3Ø Go NoGo GaugeThe Green Go end should fit into the holeThe Red NoGo end should not fit into the holeKey in either a Y (yes) or N (No) as per step 16 into FRS


22 Gauge Check Cup1 Inside hole &record

Check Cup1 Inside hole using the 11Ø Go NoGo GaugeThe Green Go end should fit into the holeThe Red NoGo end should not fit into the holeKey in either a Y (yes) or N (No) as per step 16 into FRS


23Gauge Check Cup1 StepDiameter & record

Check Cup1 Step Diameter using the 10.1Ø Go NoGo GaugeThe Green Go end should fit into the holeThe Red NoGo end should not fit into the holeKey in either a Y (yes) or N (No) as per step 16 into FRS


24 Visually Inspect Cup1 Chamfer + Radii + Undercut & record

Visually Inspect Cup1 Chamfer + Radii + Undercut using the magnifying eye glassKey in either a Y (yes) or N (No) as per step 16 into FRS


Safety or M.S.S Quality Point Knack/sensitivity point Environmental pointRevision (See detail in revision box)

Continue to machine cups Select Tool that requires Offset changeother 2 cups from each CNC machine




will be changed resulting in possible scrap

STF070 - M ethod Sheet Template / Feb 2014 / Issue3

Document Classification:Internal

PAGE 5 OF 7




Job Name Cup Dimension Check & CNC Tool Offset LineTransducer Assembly

Rev 1 New method sheet SF 12.5.15 TP

Q-Pulse No. STMS333

OP№ Op110 COSHH REF STCoSHH18,19 MHV Time


25 26 27

Measure & Record Cup 2 Dimensions Complete The FRS input Return measured Cups & fit labels

28 29 30

Measure & Record Cup Dimensions for the

T0606 - Part-OffT0505 - Turn Diameter

T0404 - Recess

T0303 - Finish Bore

T0202 - Rough Bore

T0101 - Drill

Materials & Equipment PPECNC Machine Mandatory PPE must be worn at all timesMitutoyo Digimatic Indicator Safety goggles to be worn at all timesFRS Linked PC Disposable organic vapour face mask (FFP2) to BS EN 149 to be worn when accessing machines or cleaningGO-NOGO gaugesCup dimension drawing Special PrecautionsCup Tray Keep cups from each CNC separate when taking measurementsGround steel block Use the Cup tray to ensure Cup1 or Cup 2 from each machine do not get mixedMagnification Eye Glass - RS 544-055 Take cup dimensions from each CNC every 2 hoursCup drawing - D000042602A


25Measure & Record Cup 2Dimensions

Measure & Record Cup Dimensions as per Steps 15-24If any dimension is close to the limit- Re-target the CNC offset using work steps 30-41If the dimension is out of limits- Re-target the CNC offset using work steps 30-41- Inform your cell leader- Scrap all cups produced on the machine since the last cup check


26 Complete The FRS input

When all dimensions from Cup 1 & 2 have been taken -Check the Dimensions on screen are as takenPress "Y" to confirm the dimensions are okWhen prompted - Press "Y" to print a cup batch labelThis will be the same as the Rod batch with the addition of the CNCthe cups were produced on

Lost traceability / Possible Scrap

27 Return measured Cups & fit labels

Place the measured (in-tolerance) cups back into a clear plastic bag and put the bag into the cup bin on the machine they were produced. Fit 1 cup label to the Bag / 1 label to the bin and place 1 inside the bag

Lost traceability / Possible Scrap

28Measure & Record Cup Dimensions for the other 2 cups from each CNC machine

Measure & Record Cup Dimensions as per Steps 7 to 24If any dimension is close to the limit- Re-target the CNC offset using work steps 30-41If the dimension is out of limits- Re-target the CNC offset using work steps 30-41- Inform your cell leader- Scrap all cups produced on the machine since the last cup check


29 Continue to machine cups

If cup dimensions were OK (Don't go to 30)Move all machined cups in the CNC into Bag of CupsTake dimension checks every 2 hours as per Steps 7-24If cup dimensions were close-to or out-of-limitRe-Target the machine using steps 30-41


30Select Tool that requires Offset change

T0101 - means Tool 1 Offset 1 - DrillT0202 - means Tool 2 Offset 2 - Rough Bore T0303 - means Tool 3 Offset 3 - Finish Bore T0404 - means Tool 4 Offset 4 - Undercut T0505 - means Tool 5 Offset 5 - Turn Diameter T0606 - means Tool 6 Offset 6 - Part-Off

Wrong tool selected means the wrong offset



+ Input

produce scrap


PAGE 6 OF 7





Q-PulseNo. STMS333

OP№ Op110



31 32 33

Press the Block Delete Button Go to tool offset page Decide Tool Offset direction

W1 = Tool 1 +X

Block Delete

Offset Setting -Z -X

34 35 36 -Z +Z

Cursor to X or Z offset Turn the Edit Protect Key 'Off' Input offset Value

numberkeys

Edit Protect Key

Cursor Keys



31 Press the Block Delete Button The machine will come to a stop after the final cup has been made

The machine will not stop

32 Go to tool offset page Press 'Offset Setting' button Delays - Tool Offsets not changed

33 Decide Tool Offset direction

See Image -Reduced bore diameters should be -X Increased bore diameters should be +X Reduced Outer diameter should be +X Increased Outer diameter should be -X Reduced depth should be -ZIncreased depth should be +Z

Wrong direction selected - Scrap

34 Cursor to X or Z offset

Use the cursor keys to select the offset (Will highlight yellow) Offset W01 = T0102 (Drill)Offset W02 = T0202 (Rough Bore) Offset W03 = T0303 (Finish Bore) Offset W04 = T0404 (Undercut) Offset W05 = T0505 (Turn OD) Offset W06 = T0606 (Part-Off)

Wrong Tool Offset selected - Scrap

35 Turn the Edit Protect Key 'Off' Turn the Edit Protect Key 'Off' The key will be horizontal

Delays - Changes to offset can't be made

36 Input offset Value

Key in the Offset amount (i.e. 0.06 meaning 0.06mm)0.01 and above is a positive value-0.01 and below is a negative valuePress the '+ Input' Button

Machine will run with incorrect offsets and



cup - causing delays

wrong dimensions causing scrap


PAGE 7 OF 7








37 38 39

Turn the Edit Protect Key 'On' Switch off Block Delete Clear the door alarm

40 41 42

Run the Machine Log the Change Check the dimension of the offset change



37 Turn the Edit Protect Key 'On' Turn the Edit Protect Key 'On' The key will be vertical

Risk of altering machine setting by mistake

38 Switch off Block Delete Press the Block Delete Button to switch off When started machine will only machine 1

39 Clear the door alarmOpen & Close the CNC doorThe Machine Alarm screen will clearThe LED on the Machine Alarm button will switch off

The machine will not run - Delays

40 Run the Machine Press the Cycle Start button Delays

41 Log the ChangeSelect the Logbook that matches the CNC (B,C,D,E) Log the CNC offset change in the CNC Logbook Confusion

42 Check the dimension of the offset change

Check the dimension of the first 2 cups for the offset that was changedIf the dimension is In-Limit, continue to run the CNCIf the dimension is Out-Of-Limit, Stop & Adjust Offsets per 30-41

Cups will be produced - Possibly to the



Check Variable #516 is 14 (A) Check Variable #516 is 14 (B)produced


PAGE 1 OF 2




Job Name CNC Shut-Down Operations Line Transducer Assembly Rev 1 New method sheet SF 27.4.15 TP




1 2 3

Shut down after the 14th cup has been

Offset

+ Button

4 5 6

Check Variable #516 is 14 (C) Press the Block Delete Button Record the total cups produced

Look here for516

Page Up

Page Down

Macro

Materials & Equipment PPECNC Machine Mandatory PPE must be worn at all timesVacuum extraction machine Safety goggles to be worn at all times

Disposable organic vapour face mask (FFP2) to BS EN 149 to be worn when accessing machines orcleaning

Special PrecautionsDo not mix batches of rods across CNC'sKeep the cups in the same batch after machiningRefer to corresponding method sheet for tool set-up / Dimension Checks / Routine Maintenance /


1 Shut down after the 14th cuphas been produced

Look at Variable 516 for the number producedFollow work steps 2 to 4 Inconsistency in Shut-Down / Start-Up

2 Check Variable #516 is 14 (A)This ensures the CNC will machine the last cup in the rod prior to shutdownPress the Offset button

Inconsistency in Shut-Down / Start-Up

3 Check Variable #516 is 14 (B) Press the + Button Inconsistency in Shut-Down / Start-Up

4 Check Variable #516 is 14 (C)

Press Macro ButtonPress the Page UP / Page Down button to locate variable #516Check #516 = 14 - If it is notContinue to machine until #516 = 14

Inconsistency in Shut-Down / Start-Up

5 Press the Block Delete Button The machine will come to a stop after the final cup has been made The machine will not stop

6 Record the total cups produced

Whilst on the variable screen - scroll to variable #507(total cups per day) using the scroll keysRecord the total cups machined for each machineGive the quantity to your cell leader at the end of the day

Unknown amount of cups produced



be yellow Zero

Cursor Keys Approx


PAGE 2 OF 2




Job Name CNC Shut-Down Operations Line Transducer Assembly Rev 1 New method sheet SF 27.4.15 TP




7 8 9

Zero the cup counter (#507) Press the Emergency Stop Turn the Compressed Air Off

507 should Air On/Off

Input Key0 Bar

E-Stop Pressto Stop Turn

CW to Release

Edit Protect Key

10 11 12

Switch the Isolator Off Turn the Vacuum System Off 0

Off On

Isolator On/Off

Materials & Equipment PPECNC Machine Mandatory PPE must be worn at all timesVacuum extraction machine Safety goggles to be worn at all times

Disposable organic vapour face mask (FFP2) to BS EN 149 to be worn when accessing machines orcleaning

Special PrecautionsDo not mix batches of rods across CNC'sKeep the cups in the same batch after machiningRefer to corresponding method sheet for tool set-up / Dimension Checks / Routine Maintenance /


7 Zero the cup counter (#507)

Cursor to #507 - 507 will highlight yellowTurn the Protect Key OffKey in Zero (0)Press 'Input' - 507 will read '0' Turn the Protect Key On

The following days cup count will be unclear

8 Press the Emergency Stop e Wait for the last cup to be machinedPress the red E-Stop button The machine could still operate

9 Turn the Compressed Air Off e Turn the Valve offThe pressure gauge will go to 0 bar The Air-Lines will remain pressurised

10 Switch the Isolator Off e Turn the switch ACW to the Off positionThe power to the CNC will shut-down Power to the CNC will be left on overnight

11 Turn the Vacuum System Off e Press the red 'stop' button on the vacuum systemThe Vacuum will stop The vacuum system will continue

12




ControlCNC 14 Cup Program

Fanuc Program guarantees the

additional cup / rod will be sustained

Engineer taught:-

To modify for New Txr cup

design

To modify to operate in

controlled out-of-hours

operations

To fault finding within Fanuc

Program

% O0005(MAIN PROGRAM) (PROGRAMMED IN AUGUST 2007 BY D.JAUCH) (MODIFIED MARCH 2015 FOR 14 CUPS PER CYCLE) (DATUMING METHODS ALSO MODIFIED) (BATCH COUNTER PER SHIFT #500) (BATCH COUNTER OVERALL #501) (BATCH COUNTER PER BAR #516) (BATCH COUNTER PER CLAMPING #517) (RAW PART AVAILABLE SENSOR #1000) (PART ARRIVED AT AXIAL ENDSTOP #1001) (AIR TROUGH THE SPINDEL ON M78) (AIR TROUGH THE SPINDEL OFF M88) (SEPARATION UNIT RAW PART SECTION M79) (SEPARATION UNIT SPINDLE SECTION M89) N20 #100=0 IF[#516EQ0]GOTO100 IF[#516GE15]GOTO100 IF[#517LT1]GOTO200 IF[#517LT2]GOTO300 GOTO105 N100(LOAD BAR) #5222=98.7(Z AXIS G54 LOADING) G54 IF[#1000EQ1]GOTO102 T1010 G0G54X0Z150 M69 M78 G4X0.5 M88 M79 G4X1 N130 IF[#1000EQ1]GOTO102 M89

G4X2 M79 G4X2 #100=#100+1 IF[#100GT5]GOTO400 GOTO130 N102 #516=1 N105(FEED TO STOP) #100=0 T1010 G0G97G54X0Z1S150M3M89 M69 G4X0.5 N110 M78M80 IF[#1001EQ1]GOTO120 #100=#100+1 IF[#100GT100]GOTO500 GOTO110 N120 M68 G0Z30M90 M88 #100=0 #517=0 GOTO50 N200 G65P0001 #517=1 #516=#516+1 #500=#500+1 #501=#501+1 #502=#502+1 #503=#503+1 #504=#504+1

#505=#505+1 #506=#506+1 #507=#507+1 GOTO50 N300 G65P0002 #517=2 #516=#516+1 #500=#500+1 #501=#501+1 #502=#502+1 #503=#503+1 #504=#504+1 #505=#505+1 #506=#506+1 #507=#507+1 GOTO50 N50 #5222=98.7(Z AXIS G54 LOADING) G54 /GOTO20 GOTO600 N400 M88M90M5 #516=0 G0Z150 #3000=101(NO BAR AVAILABLE) N500 M88M90M5 #516=0 G0Z150 #3000=102(BAR DID NOT REACH THE BAR STOP) N600 G0Z150 M30 %

%O0002(CUP 2)#5221=0.030(X OUTSIDE CUP 2G54)#5241=0(X INSIDE CUP 2 G55)#5222=89.3(Z AXIS CUP 2 G54)#5242=89.3(Z AXIS CUP 2 G55)G18G40G80G50S5000G55T0101M5M77G0X8.9Z2G1G98Z-4.54F400G0Z15M87G55T0202G0G97X10.9Z5S3500M3G0Z0.5G1G99Z-3.4F0.08

G1X10G1Z-3.95G1X3G0Z2G55T0303G0G97X14.4Z1S3500M3G1G99Z0F0.06G1X11G1Z-3.4625G1X10.04G1Z-4.0125G1X2G0Z2G55T0404G0G97X10.1Z1S3500M3G0Z-3G1G99Z-4.1545F0.06

G0Z-4G0X9.5Z2G54T0505G0G97X16Z-9.1S3500M3G1G99X10F0.04G4X0.2G0X16G0Z11G54T0606G0G97X16Z-8S3500M3G1G99X2F0.05G1X-2F0.03M80G0X16G4X0.2G0Z10M5M90M99%

%O0001(CUP 1)#5221=0(X OUTSIDE CUP 1

G54)#5241=0(X INSIDE CUP 1 G55)#5222=98.7(Z AXIS CUP 1 G54)#5242=98.7(Z AXIS CUP 1 G55)G18G40G80

G50S5000G55T0101M5M77G0X8.9Z2G1G98Z-4.54F400G0Z15M87G55

T0202G0G97X10.9Z5S3500M3G0Z0.5G1G99Z-3.4F0.08

G1X10G1Z-3.95G1X3G0Z2G55T0303G0G97X14.4Z1S3500M3G1G99Z0F0.06G1X11G1Z-3.4625G1X10.04G1Z-4.0125G1X2G0Z2G55T0404G0G97X10.1Z1S3500M3G0Z-3G1G99Z-4.1545F0.06

G0Z-4G0X9.5Z2G54T0505G0G97X16Z-9.1S3500M3G1G99X10F0.04G4X0.2G0X16G0Z11G54T0606G0G97X16Z-8S3500M3G1G99X2F0.05G1X-2F0.03M80G0X16G4X.2G0Z10M5M90M99%


ControlKano Model Summary

1- Existing 13 cup program 2- Proven achievement of 14 cups / rod

3- As 2 plus removal of single point of failure 4- As 3 plus Engineers trained to re-program & fault find

1

2

4

Customer Satisfaction

Degree Of

Achievement

Unspoken

Spoken

Unspoken

Excitement

Performance

Basic

Very Satisfied

Not at all

Very Dissatisfied

Fully

3

1. Existing 13 cup program

2. Proven achievement of 14

cups / rod

3. As 2 plus removal of single

point of failure

4. As 3 plus Engineers trained

to re-program & fault find


ControlProject Continuity/Sustenance

Eliminate potential failure modes

(Hierarchy)

Train / Increase the of primary

responsibilities

Train / Increase the of primary

responsibilities

Reduce dependence on

external support

Clear responsibilities across shifts

Clear GAP visibility

Clear indication of succession

Task Primary Landis Secondary Landis Primary Gyr Secondary Gyr SupportCNC Start-Up Joy S Vitali N John C - -CNC Cup-Check Joy S Vitali N John C - -CNC Tool Offset Joy S Vitali N John C - -CNC Shut Down Joy S Vitali N John C - -CNC Tool Setting (Same Tooling) Joy S Vitali N John C - -

CNC Non-Routine Maintenance Joy SAdam Lenton / Tony

Ponsonby John C

Adam Lenton / Tony Ponsonby

Simon CNC

CNC re-programming - - - - Simon CNCCNC Tool Setting (New Tooling) - - - - Simon CNCCNC Fault Finding - - - - Simon CNCCNC Non-Routine Maintenance L+G Maintenance Tony Ponsonby L+G Maintenance Tony Ponsonby Simon CNC

Task Primary Landis Secondary Landis Primary Gyr Secondary Gyr SupportCNC Start-Up Vitali N / Joy S Tony Ponsonby Pete B / John C Tony Ponsonby Simon CNCCNC Cup-Check Vitali N / Joy S Tony Ponsonby Pete B / John C Tony Ponsonby Simon CNCCNC Tool Offset Vitali N / Joy S Tony Ponsonby Pete B / John C Tony Ponsonby Simon CNCCNC Shut Down Vitali N / Joy S Tony Ponsonby Pete B / John C Tony Ponsonby Simon CNCCNC Tool Setting (Same Tooling) Vitali N / Joy S Tony Ponsonby Pete B / John C Tony Ponsonby Simon CNC

CNC Routine Maintenance Vitali N / Joy SAdam Lenton / Tony

PonsonbyPete B / John C



CNC re-programming Tony Ponsonby - Tony Ponsonby - Simon CNCCNC Tool Setting (New Tooling) Tony Ponsonby - Tony Ponsonby - Simon CNC

CNC Fault Finding / Tony Ponsonby /

Vitali N / Joy SL+G Maintenance

Adam Lenton / Tony Ponsonby / Pete B /

John CL+G Maintenance Simon CNC

CNC Non-Routine MaintenanceAdam Lenton / Tony Ponsonby / Vitali N

/ Joy SL+G Maintenance

Adam Lenton / Tony Ponsonby / Pete B /

John CL+G Maintenance

L+G Maintenance / Simon CNC

Responsibility Matrix - After DMAIC Project

Responsibility Matrix - Before DMAIC Project


Project Summary (Tangible Benefits) Increased cup yield by 1 (14 cups/rod) Saved £20,844/Yr (based on 600 additional cups/day) Allows the business to make up to 4200 meter / day (zero scrap) Facilitate an additional 108k Meters /Annum – Which represents an increase of

£7,187,400 per year (Revenue) or £3,370890.6 (Contribution to Margin) - based on G370)

Reduced cycle-time cup machining by 4.8% - prolonging future CNC investment Reduced rod waste by 82.4kg Eliminated SPoF on both shifts (>16.1 days lost in 2014 due to lack of training) Introduced SOP’s Trained L+G staff to maintain CNC production

Documents

LSS Yellow Belt Project