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Six Sigma Green Belt Project
1250-XX CoversReduction of Raw Material Cost by
Utilizing Regrind
Green Belt Candidate, Tempe
07/13/07
-Define-
The purpose of this project is to determine if the blending of 25% regrind into the GE Ultem 1000 will significantly change the Key dimensional and visual characteristics of the 1250-XX covers. We will focus on the 1250-05 for data collection as this is our highest volume part for this Customer in this category.
If successful, this will eliminate the scrapping of the GE Ultem 1000 runners plus reduce the amount of virgin material necessary to complete the orders.
-Process Map- Material Purchasing
-Measure-MSA Instructions
Instructions:-Using the Zeiss CMM program 1250-05 Six Sigma Post Only, run sample parts in order. Samples are identified 1-10.Setup (See pictures below):Place 1.500” spacer in H2.(2x .750”)Place .750” spacer in H7. Position 1250-05 sample upside down on spacer with gate at 45 degree angle to the bottom left. Snug down with second .750” spacer. Follow instructions contained in program for Base Alignment criteria.
Gate at 45 Degrees
-Measure- Measurement System Analysis
.010
K. Miller5-25-07
Zeiss
Misc:Tolerance:
Reported by:Date of study:
Gage name:
2.802
2.801
2.800
MikeKelleyBiljana
Xbar Chart by Oper.
Sa
mp
le M
ea
n
Mean=2.801UCL=2.801LCL=2.801
0.00015
0.00010
0.00005
0.00000
MikeKelleyBiljana
R Chart by Oper.
Sa
mp
le R
an
ge
R=4.67E-05
UCL=1.52E-04
LCL=0
MikeKelleyBiljana
2.8015
2.8010
2.8005
2.8000
Oper.
By Oper.
109876543211098765432110987654321MikeKelleyBiljana
2.8015
2.8010
2.8005
2.8000
Part IDOper.
By Part ID (Oper.)
%Contribution
%Study Var %Tolerance
Part-to-PartReprodRepeatGage R&R
100
50
0
Components of Variation
Pe
rce
nt
Gage R&R (Nested) for 2.798 +/- .0
Measurement System Analysis cont’d.Less than 10% of the tolerance is taken up by measurement
error indicating that the Zeiss CMM program is an acceptable way to accurately measure the Key characteristics.
Gage R&R %ContributionSource VarComp (of VarComp) Total Gage R&R 0.0000000 0.99 Repeatability 0.0000000 0.99 Reproducibility 0.0000000 0.00 Part-To-Part 0.0000002 99.01 Total Variation 0.0000002 100.00
StdDev Study Var %Study Var %Tolerance
Source (SD) (5.15*SD) (%SV) (SV/Toler) Total Gage R&R 0.0000483 0.0002488 9.95 2.49 Repeatability 0.0000483 0.0002488 9.95 2.49 Reproducibility 0.0000000 0.0000000 0.00 0.00 Part-To-Part 0.0004832 0.0024885 99.50 24.88 Total Variation 0.0004856 0.0025009 100.00 25.01
Number of Distinct Categories = 14
-Measure-Key Dimension Capability using 100%
Virgin Material
151050
2.8017
2.8016
2.8015
2.8014
Xbar and R Chart
Subgr
Mea
n
Mean=2.802
UCL=2.802
LCL=2.801
0.00024
0.00016
0.00008
0.00000
Ran
ge
R=6.92E-05
UCL=2.26E-04
LCL=0
151050
Last 15 Subgroups2.80165
2.80155
2.80145
2.80135
Subgroup Number
Val
ues
2.8032.793
Capability PlotProcess Tolerance
III
III
IISpecif ications
Within
Overall
2.80162.80152.8014
Normal Prob Plot
2.80162.80152.8014
Capability Histogram
WithinStDev:Cp:Cpk:
0.000061427.17 8.01
OverallStDev:Pp:Ppk:
0.000064625.79 7.61
Process Capability Sixpack for 2.798(100%V)
-Measure-Key Dimension Capability using 100%
Virgin Material
151050
0.1380
0.1378
0.1376
0.1374
Xbar and R Chart
Subgr
Mea
n
1
Mean=0.1377
UCL=0.1380
LCL=0.1373
0.0006
0.0004
0.0002
0.0000
Ran
ge
R=1.81E-04
UCL=5.92E-04
LCL=0
151050
Last 15 Subgroups0.1380
0.1378
0.1376
0.1374
Subgroup Number
Val
ues
0.1400.136
Capability PlotProcess Tolerance
III
III
IISpecif ications
Within
Overall
0.138000.137750.13750
Normal Prob Plot
0.13800.13760.1372
Capability Histogram
WithinStDev:Cp:Cpk:
0.00016064.153.44
OverallStDev:Pp:Ppk:
0.00017863.733.10
Process Capability Sixpack for .140(100%V)
-Measure-Key Dimension Capability using 100%
Virgin Material
151050
0.0074
0.0072
0.0070
0.0068
Xbar and R Chart
Subgr
Mea
n
Mean=0.007065
UCL=0.007337
LCL=0.006793
0.00045
0.00030
0.00015
0.00000
Ran
ge
R=1.45E-04
UCL=4.72E-04
LCL=0
151050
Last 15 Subgroups0.0073
0.0071
0.0069
0.0067
Subgroup Number
Val
ues
0.010.00
Capability PlotProcess Tolerance
III
III
IISpecif ications
Within
Overall
0.007300.007050.00680
Normal Prob Plot
0.00740.00700.0066
Capability Histogram
WithinStDev:Cp:Cpk:
0.000128113.01 7.63
OverallStDev:Pp:Ppk:
0.000120213.87 8.14
Process Capability Sixpack for Parallel(100
-Measure-Key Dimension Capability using 25%
Regrind
151050
2.8015
2.8014
2.8013
2.8012
Xbar and R Chart
Subgr
Mea
n
1
Mean=2.801
UCL=2.801
LCL=2.801
0.0003
0.0002
0.0001
0.0000
Ran
ge
R=8.01E-05
UCL=2.62E-04
LCL=0
151050
Last 15 Subgroups
2.8014
2.8013
2.8012
2.8011
Subgroup Number
Val
ues
2.8032.793
Capability PlotProcess Tolerance
III
III
IISpecif ications
Within
Overall
2.80152.80132.8011
Normal Prob Plot
2.801502.801252.80100
Capability Histogram
WithinStDev:Cp:Cpk:
0.000071023.47 7.88
OverallStDev:Pp:Ppk:
0.000089418.65 6.26
Process Capability Sixpack for 2.798(25%R)
-Measure-Key Dimension Capability using 25%
Regrind
151050
0.13775
0.13750
0.13725
0.13700
Xbar and R Chart
Subgr
Mea
n
Mean=0.1374
UCL=0.1377
LCL=0.1370
0.0006
0.0004
0.0002
0.0000
Ran
ge
R=1.95E-04
UCL=6.37E-04
LCL=0
151050
Last 15 Subgroups0.1376
0.1374
0.1372
0.1370
Subgroup Number
Val
ues
0.1400.136
Capability PlotProcess Tolerance
III
III
IISpecif ications
Within
Overall
0.13780.13740.1370
Normal Prob Plot
0.137500.137250.13700
Capability Histogram
WithinStDev:Cp:Cpk:
0.00017283.862.64
OverallStDev:Pp:Ppk:
0.00017583.792.60
Process Capability Sixpack for .140(25%R)
-Measure-Key Dimension Capability using 25%
Regrind
151050
0.00735
0.00710
0.00685
0.00660
Xbar and R Chart
Subgr
Mea
n
Mean=0.006979
UCL=0.007317
LCL=0.006640
0.0006
0.0004
0.0002
0.0000
Ran
ge
1
R=1.80E-04
UCL=5.88E-04
LCL=0
151050
Last 15 Subgroups0.00755
0.00730
0.00705
0.00680
Subgroup Number
Val
ues
0.010.00
Capability PlotProcess Tolerance
III
III
IISpecif ications
Within
Overall
0.00760.00710.0066
Normal Prob Plot
0.00760.00710.0066
Capability Histogram
WithinStDev:Cp:Cpk:
0.000159710.44 6.31
OverallStDev:Pp:Ppk:
0.000166210.03 6.06
Process Capability Sixpack for Parallel(25%
-Measure-Key Dimension Capability using 100%
Regrind
151050
2.8018
2.8016
2.8014
2.8012
Xbar and R Chart
Subgr
Mea
n
1
Mean=2.801
UCL=2.802
LCL=2.801
0.0003
0.0002
0.0001
0.0000
Ran
ge
R=1.10E-04
UCL=3.59E-04
LCL=0
151050
Last 15 Subgroups2.8018
2.8016
2.8014
2.8012
Subgroup Number
Val
ues
2.8032.793
Capability PlotProcess Tolerance
III
III
IISpecif ications
Within
Overall
2.801702.801452.80120
Normal Prob Plot
2.801702.801452.80120
Capability Histogram
WithinStDev:Cp:Cpk:
0.000097517.10 5.19
OverallStDev:Pp:Ppk:
0.000127113.12 3.98
Process Capability Sixpack for 2.798(100%R)
-Measure-Key Dimension Capability using 100%
Regrind
151050
0.1378
0.1376
0.1374
0.1372
Xbar and R Chart
Subgr
Mea
n
Mean=0.1375
UCL=0.1378
LCL=0.1372
0.0006
0.0004
0.0002
0.0000
Ran
ge
R=1.60E-04
UCL=5.24E-04
LCL=0
151050
Last 15 Subgroups0.1378
0.1376
0.1374
0.1372
Subgroup Number
Val
ues
0.1400.136
Capability PlotProcess Tolerance
III
III
IISpecif ications
Within
Overall
0.137700.137450.13720
Normal Prob Plot
0.137700.137450.13720
Capability Histogram
WithinStDev:Cp:Cpk:
0.00014224.693.55
OverallStDev:Pp:Ppk:
0.00019153.482.64
Process Capability Sixpack for .140(100%R)
-Measure-Key Dimension Capability using 100%
Regrind
151050
0.0072
0.0070
0.0068
0.0066
Xbar and R Chart
Subgr
Mea
n
1
Mean=0.006941
UCL=0.007158
LCL=0.006723
0.00045
0.00030
0.00015
0.00000
Ran
ge
R=1.16E-04
UCL=3.78E-04
LCL=0
151050
Last 15 Subgroups0.0072
0.0070
0.0068
0.0066
Subgroup Number
Val
ues
0.010.00
Capability PlotProcess Tolerance
III
III
IISpecif ications
Within
Overall
0.007100.006850.00660
Normal Prob Plot
0.007100.006850.00660
Capability Histogram
WithinStDev:Cp:Cpk:
0.000102616.24 9.94
OverallStDev:Pp:Ppk:
0.000118614.05 8.60
Process Capability Sixpack for Parallel(100
-Analyze-A t-Test is being used to show that there is no significant difference
in the means between the 100% Virgin material and the Virgin material with 25% Regrind. With the P-value being greater than
Alpha (.05), we fail to reject the Null Hypothesis (Ho) on all 3 Key Characteristics.
-Analyze-Cont’d.
-Analyze-Cont’d.
Samples were run with 100% Regrind to see what effect it had on the Key Characteristics. t-Tests were used to show if a significant
difference in the means had been caused by the change. With P-values remaining greater than Alpha (.05), we fail to reject the Null
Hypothesis (Ho) on all 3 characteristics proving there is no significant difference in dimensional readings when 100% Regrind is used.
-Analyze-Cont’d.
-Improve-The Improvement phase will implement the usage of 25% Regrind
added to the virgin material during normal production runs. The Work Order template will be updated in the Shared Directory to accurately reflect the percentage of regrind allowed. Correct usage of material will be verified during the QA Sign-In and
initialed. The Bill of Materials will also be amended.
-Control-
The Customer defined ‘Key Characteristics’ will be monitored after the introduction of regrind during the molding operation using
a variety of tools. Sign-In and In-Process dimensional inspection criteria are controlled and communicated via the Mold Data Book. The QA Sign-In at the start of the run will include the
Customers current A-079 inspection form available from their Customer Website. In-Process data will be entered into real-
time SPC Charts in the Quality Control Lab and will be monitored by Quality Inspectors. Any unusual variation in the SPC Charts will be investigated. Out of specification product
will be quarantined and properly labeled with an Non Conforming Material Report per the ISO standard and
dispositioned accordingly.
-Control-Copy of Mold Data Book Page-
In-process Dimensional Inspection criteria.
Copy of Mold Data Book Page- Sign-In Criteria
-Control-Sample Customer A-079 Inspection Form
-Control-
Sample SPC Chart
Copy of Blank NCMR
-Cost Savings-
-Cost Savings-Extrapolated to include all the 1250-XX Covers that do not specify
‘100% Virgin Only’ including -02, -05, -08, -10, -11, -12:
-Conclusion-After measuring samples run with 25% Regrind/75% Virgin and
samples run with 100% Regrind, it has been concluded that there were no significant differences or changes in the
Customer’s Key Dimensions. Cpk levels ranged between 2.64 and 9.94 indicating all values are well above the 2.00 Cpk of a stable 6-sigma process. Taking into account normal process variation and the likeliness that the process may drift, it can
be assumed that the values will remain within the Customer’s specifications.
Tensile strength testing will need to be done by the Customer to verify overall strength and integrity has not been
compromised due to this change.With an annual savings of $5,687.34 for the -05 configuration,
the potential cost savings if applied to all of the 1250-XX part numbers would be $13,655.25 annually.