Secreti _GB Project9_7_16-1

Reduce Scrapped Filler B30 WPProject ID: 4168

GB Final presentation Template

Copyright 2010 Momentive Performance Materials Inc. All rights reserved. CONFIDENTIALD M A I C2May 2, 2023 2

• Problem Statement: Approximately 216,000 lbs of filler is scrapped annually in Bldg. 30 through the dust collector system. This filler is estimated to be worth $563,000

• Objective: Reduce lost filler on the B30 WP North dust collector from 433 lbs per day to 201 lbs per day by June 30, 2012.

• Background Information: This has been an ongoing problem for years. The operators and CO’s have requested a serious look and remedy.

• Metric: Lbs lost filler per day• Annualized Stake: The amount of filler scrapped: 2.16 boxes x 201 lbs = 434 lbs 88049 434 lbs x $2.32 (avg cost/lb) x 180 days x 50% = $91M

88138 434 lbs x $2.90 (avg cost/lb) x 180 days x 50% = $113M $22.83 (cost box/pallet/bag) x 425 (reduction) = $10MTotal $214M per year

• Business: SQD• Location: Waterford• Benefit Type : Processing Costs RTA #: 4168• Approval:

– MBB: MJ Pis– Finance: W. Carl Validated: No– Champion: Nicole Ol / Kevin A– Author: B. Secreti

Project Overview

Copyright 2010 Momentive Performance Materials Inc. All rights reserved. CONFIDENTIAL 3 3

Metric Graph based on Production Data

2.16 boxes per day average (434 lbs)

Copyright 2010 Momentive Performance Materials Inc. All rights reserved. CONFIDENTIALD M A I C4

Thought Map

WHAT DO WE KNOW?

• FILLER LOSS 600# APROX PER DAY

•SCRAPPED INTO NORTH DUST COLLECTOR

• SOUTH VERY LITTLE

• NUMBER OF TOTES RELATED TO PRODUCTION LEVELS

• AMOUNT OF WASTE NOT TRACKED BY BUILDING.

LOST FILLER?

WHAT DON”T WE KNOW?• WHY

• EXCACTLY HOW QUANTIFY

• EFFECTS ON ALL CUSTOMERS

KEY QUESTIONS

•HAS FILLER LOSS BEEN LOOKED AT BEFORE?

•HAS FILTER MANUFACTURE SEEN THIS ISSUE?


SIPOCSCRAP FILLER REDUCTION

SUPPLIERS INPUTS PROCESS OUTPUTS CUSTOMERS

•B-30 TREATED FILLER•WP OPERATIONS• TOTE SUPPLIER•INVESTOR$• FUMED SILICA•POLY HOUSE•SHIPPERS •WAREHOUSE•YARD CREW

88049 FILLER88318 FILLERTOTES PLASTIC BAGSDRUMSBOXESTOPSLABOR HOURSLOGISTICAL RESOURCESUTILTIES

•LIQUIDS•OILS•FILLER•HEAT•COOLING•LABOR•ENGINEERING

PALLETSCARDBOARDPLASTICSEALANT &ADHEASIVEPRODUCTSCOATINGSGENERATED WASTE

P&GANDERSONWWTPYARD CREWSHIPPERSRECEIVERSBLD MANAGERMAINTENANCEWAREHOUSEENVIORMENTENGINEERINVESTOR$

FILLER TO FILTERS DURING WP-30 MANUFACTURING PROCESS OWNER: KEVIN ALLEN

Copyright 2010 Momentive Performance Materials Inc. All rights reserved. CONFIDENTIALD M A I C

Dust collector


M3 - Specify the customers needs

Project Y

The project Y is amount of scrapped filler. Reducing this is a direct cost savings.

Specification Limits

Since the area is currently satisfied with the current performance, specification limits are arbitrary. The real specification is as low as possible. Discussions with the vendor have indicated we should be able to get down to one box per day.


MSA

8

The actual amount of filler leaving the plant is measured using a truck scale located at Imperial Landfill in Pennsylvania. Decided to use the MSA method for instrumentation because we don’t have a way to do a standard MSA on this scale.

This method requires the following (answers from phone interview with facility manager):

• Is the instrument installed properly – it was professionally installed and maintained

•Is the instrument calibrated at the proper frequency – the state of PA requires annual calibration, the landfill’s procedure is to calibrate quarterly.

•Is this the right instrument for the application – yes

•Are there any known problems with the instrument - no


MSA

Based on the answers to the previous questions, we can use the following equations to calculate the


MSA - % Study Variation

Calculating the overall standard deviation Y -

Y = 5740

meas = +/- 60 x 2 / 6 = 20 lbs

% Study Variation = 20/5740 = 0.3% !!

This is <10%, so very acceptable


MSA - % Tolerance

To calculate % Tolerance, we first need to determine specification limits. Our goal is to move the average, not set an upper or lower specification, so we’ll need to make some assumptions

Current average = 434 lbs per day

Target average = 201 lb per day

USL = 402 lbs LSL = 0 lbs

This may seem like a large range, but an average truck contains 7500 lbs, so it is really only +/- 5%

% Tolerance = 5.15*20 / 434 = 24% - also acceptable, but barely

MSA shows the measurement system is acceptable


Capability analysis

Is the data normal?

NO

And no transformation worked on the data either

Also, no rational subgroups appeared in the data

Likely due to the way in which the data is generated and collected


Capability analysis

Do it anyway

Data looks nearly normal (these values are within 100,000)

Zbench = -0.11, not so good

Current process is not capable


Capability analysis

Shifting the mean, will have to happen to meet the goal

Zbench = 0.52, better

30% out, better than 54%


Capability analysis

Shifting the mean and improving standard deviation

Zbench = 2.00, even better

96% DPMO reduction if we can shift the mean and tighten up the standard deviation


PROCESS MAP

TREATEDFILLER

B-30 SILOS

OMYA

NORTH HOPPER

BIN VENT

EASTHOPPER

BIN VENT

SOUTH HOPPER

BINVENT

Funnel To machine

Wp I

Dust collectorEmpty dustcollectors

Scrapfiller

Box For

Transfer

Shipped toPenn.

LEE Q

KEVIN A

TOM L#1

BOB SECRETI


C&E Matrix or FMEA or Fishbone

Measurement

Filler to dust collector.

*Dust collector; not a filler collector

Mother Nature

Warmer weather =

Clumping of product 4

Machine

Larger pipe then reduced. 1

Higher velocity of air flow 1

2500 cfm

Materials

88049 88318 4Omya pfinly

Boxes covers bags tape filters

Method

Improved piping 1Eliminate piping 2

People

Breathing dust lost productivity

4Shipping cost

internal external

Wp I B-30

Scrap filler

Reduction

1 3

2 4

IMPACT

EASE


X’s to Carry Forward

Improved piping – small expense, no investment – good first choice to pursue

Other x’s not to be pursued at this time:

Decreasing air flow velocity – needs investment for Variable Frequency Drive and instruments

Elimination of some piping – requires re-engineering and some investment


New part


As installed


Project Performance

Scrapped Filler

0

2000

4000

6000

8000

10000

12000

14000

16000

1800020

11FW

01

2011

FW05

2011

FW09

2011

FW13

2011

FW17

2011

FW21

2011

FW25

2011

FW29

2011

FW33

2011

FW37

2011

FW41

2011

FW45

2011

FW49

2012

FW01

2012

FW05

2012

FW09

2012

FW13

2012

FW17

2012

FW21

2012

FW25

Fiscal Week

Poun

ds F

iller

BoxesBaselineExpected

Since the change


Post Installation Capability Analysis

Expected DPMO down from 540,000 to 452

Zbench up from –0.11 to 3.32


Hypothesis Testing

H0 – the data is the same before and after the change

Ha – the data set since the change is statistically different than before the change

Confidence Interval for the difference

does not include 0

P is low – the null must go !

The data sets are different


Control chart

New Process shows good

control


Control Plan


Project Summary

•Achieved reduction in filler boxes per day from 2.16 to 0.4 per day

•Savings tracking to over $400,000 per year in 3 areas:

•$400,000 in filler that isn’t being scrapped

•$14,000 in packaging for filler no longer being scrapped

•$40,000 is waste fees no longer being spent

• 92% DPMO Reduction

•Zbench up from –0.11 to 3.32


Thoughts on the Methodology

I had expert Master Black Assistance with the statistical portion.

It was a combined effort with data and math. Dave M. helped me.

Thanks Dave

The Green Belt system tools are instrumental in focusing and solving on going issues with cost and productivity. All the folks connected with the organization were concerned and very helpful.


Summary Slides

• Power Required Standard available voltages 208/230/460/575/400:• 50/60 Hz; 3 Phase• Horsepower Required 3 - 200 HP• Keypad Two user set-points; High and Low. Up and Down• Arrow keys; programmable from front panel• Pressure Range 0-20” wg operating scale controls fan speed based• on system static pressure at dirty air plenum• Output Signal 4-20 mA for remote indication of static pressure• External Inputs Remote contact closure to lock setpoints• Environmental Rating Indoor installation only (NEMA Type 12)• Operating Temperature 32°F - 90°F (0-32°C)• Humidity 0-85%, non-condensing• Altitude 3,280 ft (<1000 Meters)• Approvals UL/CUL •


base FEATURES & OPTIONSbase standard optionalAirflow Controller Window for VFD DisplayVFD (with soft-start capability) properly sized for application Face-Mounted VFD Keypad(changes enclosure rating to NEMA Type 1)Torit Delta P or Delta P Plus On-Demand Cleaning Custom Configurations• Additional Components• Company Specific Components• Other Enclosure Ratings• Additional Motor Starters• Additional Horsepower Available

Copyright 2010 Momentive Performance Materials Inc. All rights reserved. CONFIDENTIAL3030

DISCLAIMER: THE MATERIALS, PRODUCTS AND SERVICES OF MOMENTIVE PERFORMANCE MATERIALS INC., MOMENTIVE PERFORMANCE MATERIALS USA INC., MOMENTIVE PERFORMANCE MATERIALS ASIA PACIFIC PTE. LTD., MOMENTIVE PERFORMANCE MATERIALS WORLDWIDE INC., MOMENTIVE PERFORMANCE MATERIALS GmbH, THEIR SUBSIDIARIES AND AFFILIATES DOING BUSINESS IN LOCAL JURISDICTIONS (collectively “SUPPLIERS”), ARE SOLD BY THE RESPECTIVE LEGAL ENTITY OF THE SUPPLIER SUBJECT TO SUPPLIERS’ STANDARD CONDITIONS OF SALE, WHICH ARE INCLUDED IN THE APPLICABLE DISTRIBUTOR OR OTHER SALES AGREEMENT, PRINTED ON THE BACK OF ORDER ACKNOWLEDGMENTS AND INVOICES, AND AVAILABLE UPON REQUEST. ALTHOUGH ANY INFORMATION, RECOMMENDATIONS, OR ADVICE CONTAINED HEREIN IS GIVEN IN GOOD FAITH, SUPPLIERS MAKE NO WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, (i) THAT THE RESULTS DESCRIBED HEREIN WILL BE OBTAINED UNDER END-USE CONDITIONS, OR (ii) AS TO THE EFFECTIVENESS OR SAFETY OF ANY DESIGN INCORPORATING SUPPLIERS’ PRODUCTS, MATERIALS, SERVICES, RECOMMENDATIONS OR ADVICE. AFOREMENTIONED EXCLUSIONS OR LIMITATION OF LIABILITY ARE NOT APPLICABLE TO THE EXTENT THAT THE END-USE CONDITIONS AND/OR INCORPORATION CONDITIONS CORRESPOND TO THE RECOMMENDED CONDITIONS OF USE AND/OR OF INCORPORATION AS DESCRIBED BY SUPPLIER IN ITS PRODUCT DATA SHEET AND/OR PRODUCT SPECIFICATIONS. EXCEPT AS PROVIDED IN SUPPLIERS’ STANDARD CONDITIONS OF SALE, SUPPLIERS AND THEIR REPRESENTATIVES SHALL IN NO EVENT BE RESPONSIBLE FOR ANY LOSS RESULTING FROM ANY USE OF ITS MATERIALS, PRODUCTS OR SERVICES DESCRIBED HEREIN. Each user bears full responsibility for making its own determination as to the suitability of Suppliers’ materials, services, recommendations, or advice for its own particular use. Each user must identify and perform all tests and analyses necessary to assure that its finished parts incorporating Suppliers’ products, materials, or services will be safe and suitable for use under end-use conditions. Nothing in this or any other document, nor any oral recommendation or advice, shall be deemed to alter, vary, supersede, or waive any provision of Suppliers’ Standard Conditions of Sale or this Disclaimer, unless any such modification is specifically agreed to in a writing signed by Suppliers. No statement contained herein concerning a possible or suggested use of any material, product, service or design is intended, or should be construed, to grant any license under any patent or other intellectual property right of Suppliers or any of its subsidiaries or affiliates covering such use or design, or as a recommendation for the use of such material, product, service or design in the infringement of any patent or other intellectual property right.

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Secreti _GB Project9_7_16-1