Therm-O-Disc Inc.

Product Engineering Dept

Performance Improvement
Six W Project EPR 17340 12D Pressure Release Thermal Sensor Engineering Analysis
Changqi John Liu, Ph.D
Created on 07/20/2005

8/25/2011 by CJL

TOD Confidential

Topics in This Presentation - Phase (1): Measurement

Project Scope(1) Problem Statement Objective Team Members Physical Concept for 12D-Temp Control and Pressure Release Valve Major Output: TFD and Its Standard Deviation Target plan Cause and Effect Diagram Process Map Analysis Process Capability Analysis On 3/4/2005 At Project Start Process Capability Analysis on 04/21/05 and Results Analysis Improvement (1)-Blank Failure Analysis Improvement (2)-Second Stress Relief Improvement (3)-Stability Process
DOE and Results analysis Process Optimization Confirmation test and results

Conclusions Project Plan in Future Phase

8/25/2011 by CJL

TOD Confidential

Project Scope
Problem Statement: 12D, Style 46338 Copeland Disc is a newly developed Product. The first temp sorting reject rate is approximately to 450,000 PPM. Annual volume estimated to reach 4.5 million in 2007. The high rate of first reject discs resulted in reworking labor increase by 6500 hour per year. The high rate of final scrap disc resulting in cost increased by $ 283,500 per year. Objective: By optimizing the process parameters to reduce first rejection scrapped discs by 10% by July 2005. This will yield about annually $97,600 cost saving per year. ( In long run, we will try to get scrap discs less than 150,000 PPM. If the final objective is reached it will generated about annually $189,000 cost reduction.

8/25/2011 by CJL

TOD Confidential

Team Members
Changqi Liu:
Sr. Project Engineer ( Mansfield ) Chen, Jianbang: Sr. Manufacture Engineer ( China ) Wu, Roy: Quality Engineer ( China ) Zhang, Shear: Process Control Engineer ( China )

Support Management
Chua, Ck: Gurski, Mike: Evans, Garry: Lean Manufacturing Manager Engineering Manager Quality Control Manager

Mansfield Support
Born, Michael; Mueck, Jeff, Disc Dept
8/25/2011 by CJL TOD Confidential 4

12D Disc with Different View Point

Snap Action at Open/Close Temp

8/25/2011 by CJL TOD Confidential 5

Disc Snap Open to Release the Pressure

8/25/2011 by CJL

TOD Confidential

Primary Metric
Sigma vs. Date
7 6

Projected Target Actual

4 Sigma

It should be here to get 6

~ 4.2 o F at the

project completion

0 3/4/2005

4/3/2005

5/4/2005

6/3/2005

7/4/2005 Date

8/4/2005

9/3/2005

10/4/2005

11/3/2005

8/25/2011 by CJL

TOD Confidential

Objected Parameter
The target of the first phase is to obtain first sorting 70 %, final yield to 80%
S No Projected W
o

Average*
o

U S Limit
o

L S Limit
o

Z Level-U

Z Level-L

PPM-U

PPM-L

PPM-T

FTY

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

6.50 6.00 5.50 5.00 4.50 4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50

275.0 275.0 275.0 275.0 275.0 275.0 275.0 275.0 275.0 275.0 275.0 275.0 275.0

268.0 268.0 268.0 268.0 268.0 268.0 268.0 268.0 268.0 268.0 268.0 268.0 268.0

278.0 278.0 278.0 278.0 278.0 278.0 278.0 278.0 278.0 278.0 278.0 278.0 278.0

W = 4.2 o F ~ 0.46
0.55 0.60 0.67 0.75 0.86 1.00 1.20 1.50 2.00 3.00 6.00

1.08

322206

140757 121673 101557 80757 59907 40059 22750 9815 2555 233 2 0 0

462964 430210 394278 355010 312399 266686 218433 168471 117625 67040 22752 1350 0

53.70 56.98 60.57 64.50 68.76 73.33 78.16 83.15 88.24 93.30 97.72 99.87 100.00

0.50 1.17 308538 1st Sorting Yield to be 70% 1.27 1.40 1.56 1.75 2.00 2.33 2.80 3.50 4.67 7.00 14.00 292720 274253 252492 226627 195683 158655 115070 66807 22750 1350 0

* Normal Center is 273 o F, It is allowed the actual center control between 272 and 275 o F

8/25/2011 by CJL

TOD Confidential

Cause Effect Diagram

8/25/2011 by CJL

TOD Confidential

Process Flow Chart

12 D Disc Style No 46338
VA
Bimetal RM Strip RM 99033 MS-10 Blanking B-3093-1

VA
Cleaning CL-355 & BF-603

Receiving Insp. MS-10, RMA-14-6

Blanking Insp. QCW C10457

VA

DPU Forming Auto Bumper

VA

DPU Heat Treatment HT 123

VA
Deburring TM-701 & BF-605

Audit / In-Process QCW B-1425, 12D 701

VA
DPU Stress Relief SR 103

VA
1st

DPU Thermal Cycle SR 105

VA

DPU 2nd Thermal Cycle SR 105

8/25/2011 by CJL

TOD Confidential

10

Process Flow Chart (2)

12D Copeland Disc, Style 46338
NVA
Tumbling or SR 103 No 4 Pot Sorting

VA

VA

DPU th Thermal Cycle 4 SR 105

VA

DPU 3rd Thermal Cycle SR 105

Yes VA Cleaning CL - 355 Dock Audit BF-609 Inspection Audit QCW B1425
Package Shipment RFU Style No 46338

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TOD Confidential

11

Process Mapping(1)-Blanking
Type ofKPIVs(Xs) CR C C C C N C N N CR CR CR C C SPECs Gages Digital Checker Optical Microscope Micro-Hardness Tester Micro-Hardness Tester Special Tester Special Method, Visual Thickness MS-10, RM14-6 Grain Size MS-10, RM14-6 HES Hardness MS-10, RM14-6 LES Hardness MS-10, RM14-6 Cross Flatness MS-10, RM14-6 Bonding Strength MS-10, RM14-6 RM Cut Layer Punches Setup Blank Number Dimple Profile Dimple Profile MS-10, RM14-6 MS-10, RM14-6 MS-10, RM14-6 Dr. B-3093 BF-701 BF-701 Dr B-3093-1 Raw Material RM 99033 KPOVS ( ys) Spec Data DPU T/WT C RTY % NVA Inspection MS-10, RM-14-6 Thickness Uniform+/-I 0.D11 Grain Size No. >8 Hardness Value 210~260 Hardness Value 260~315 Cross Curvature < 0.008" De-layminated Dimple Height Profile Hx Profile Hy Diameter D Number Per Bag Dimple Height Profile Hx Profile Hy B-3093 B-3093 B-3093 B-3093 <2500 PC 12D-702 12D-702 12D-702 0.005 1 Days CT 99.5

Visual Control Visual Control Profilimeter System Control Weight Control Profilimeter Profilimeter

VA

DPU Stamping

0.001 1440 Min

99.99

NVA Blank Audit QCW-10457

0.0005 240 Min

99.95

C C C

No/Bab BF 701 Time CL-355 Surface Conditio CL-355

Weight Control System Control Visual

VA

Cleaning CL-355, BF603

Visual Checking

CL-355

0.002 45 Min

99.8

CR C C C C C

Temp Times Heating Rate Cooling Rate Volume of HT

HT123 HT123 HT123 HT123 HT123

Oven Meter System Control Volume Per Tray Wind Cooling Weight Control BF 701 Set Timer

VA Heat Treatment

Formability VA Deburing

>320 o F

0.05 60 Min

95

Pieces/Bag BF 705 Vib. Frequency BF 706 Time BF 707

Round Corner Radii

5E-04 45 Min

99.95

Total

Store Room BF 605

0.054 3 Days

94.6

8/25/2011 by CJL

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12

Process Mapping(2)-Calibration

8/25/2011 by CJL

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13

PFMEA(1)
A B Potential Failure Mode(s) C Potential Effect(s) of Failure D S e v 8 E Potential Cause(s)/ Mechanism(s) of Failure F O c c 1 G Current Process Controls Press operator checks dia. and profile. H D e t 1 I R P N 8 J Recomme nded Action(s)

Item # 1

Process Function Requirements Blanking

Blank Dimension out of specification

Disc will not operate correctly

Tooling dimensions incorrect

2
Cleaning Oil or contamination present

Disc oil and contamination

Cleaning process has poor filtration.

Q.A. Visual Inspection

3 2

Contact maintenan ce

3
Deburring

Edge burr exceeds .001"

Disc operation effected by sharp edge

Vibration time too short Punch tool is dull resulting in too much burr Disc equipment tooling wear.

Deburr operator check Burr

1 0

Tooling needs grinding.

Forming conditions chan e. Formin ability too low Discs are Wrapped

Could not form the disc Conveyer not s ooth to deliver Diff n FD/BFD f each disc res l in s andard deviati n wide

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Coolin Rate Chan ed

Heat Treatment

Forming ability Changed

Too high Temp, EQ. Out of Control Too Low Temp, EQ out of Control

Metrology Instron check every 20th lot

2 8

Contact maintenan ce

14

Improvement (1) Effect of RM and Blanking RM Thickness Uniformity Parameter Uniformity Blank Number of Blank Disc Per Bag HY Lesson Failure Analysis Large Number Risk
Low Yield Disc Unstable

It is not the HT and Cleaning Process that depend the Number of Blank Per Bag. It is Major the RM Parameter variation to Determine the Number Per Bag Blank Number Should be Optimized, A Plan was sent to China plant to do tests Yield vs. Number of Blank per Bag
8/25/2011 by CJL TOD Confidential 15

Improvement(2) Second Time Stress Relief

 Second Time Stress Relief was done in China

Plant which was originally used to correct the bad HY blank. After the blank was corrected, it is still being used in production.  To increase the stability of disc.  It can be get more upper and lower limit from 268/276 to 268/278 in process.  It is proved to increase the life cycles also.

8/25/2011 by CJL

TOD Confidential

16

Process Analysis Step by Step on 4/21/05

PRA AsFed AS-SR As-1stC As-2ndC As-3rdC As-4thC 1stST
o

F 273.48 7.14 287.40 257.80 29.60 275.49 6.14 288.70 265.20 23.50 275.37 5.10 286.90 267.30 19.60 276.09 4.98 287.10 267.80 22.30

Average Stdev Max Min Range

297.73 7.69 301.10 294.50 6.60

276.49 7.24 290.20 264.40 25.80

272.45 5.87 285.30 258.70 26.60

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TOD Confidential

17

Process Capability at 4/25/05

P r oce ss Capability F or 1 2 D 4 6 3 3 8 Disc The rmal S e nsor
(using 95.0% confidence)
LS L P rocess D ata LS L 267.00000 T arget * USL 283.00000 S am ple M ean 273.40000 S am pleN 120 S tD ev (Within) 5.25000 S tD ev (O v erall) 5.12431 USL W ith in O v er all P otential (Within) Cp Low erC L U pperC L C PL C PU C pk Low erC L U pperC L C C pk C apability 0.51 0.44 0.57 0.41 0.61 0.41 0.33 0.49 0.51

O v erall C apability Pp Low erC L U pperC L PPL PPU P pk Low erC L U pperC L C pm Low erC L 0.52 0.45 0.59 0.42 0.62 0.42 0.34 0.50 * *

264
O bserv ed P erform ance P P M < LS L 125000.00 P P M > U S L 25000.00 P P M T otal 150000.00

268

272

276

280

284

E xp. Within P erform ance P P M < LS L 111413.06 P P M > U S L 33731.92 P P M T otal 145144.98

E xp. O v erall P erform ance P P M < LS L 105842.15 P P M > U S L 30505.13 P P M T otal 136347.28

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18

Plan in Improvement Phase

Blank Number Optimization: WAs formed vs. number of blanks per bag (1500, 1750, 2000, 2250 pieces/bag) HT Temp Optimization
Use Appropriated HT System to get the right Open and Differential ( 275/100 o F) Special for 12D 46338

Punch Effect and Optimization SR and Stability Optimization Combination Effect DOE Test
To get best two levels for above four factors to do the design of experimental
8/25/2011 by CJL TOD Confidential 19

Improvement (3)
Design Experiment Analysis
Affecting Factors
HT Temp, Time, Temp Creasing, Cooling Rate, Number per container Forming Conditions Penetration 1 and Penetration II Punch effect: Spherical Radium of 1st Punch SR Temp, Time, Temp Increasing Rate, Cooling Rate Number Per Basket Thermal Cycles Cycle time, Temp, Number Per Basket

If each factor takes 2 levels, it will be 215 tests. It is too many tests to be performable. We need a Blocking Method.
8/25/2011 by CJL TOD Confidential 20

DOE Analysis
In this phase, the DOE will focus on SR and Thermal Cycles Factors selected
Number of Disc Per Container SR - Temp Thermal Cycle Temp and Cycle Times

Altogether four factors, Each factor has two levels, The Complete tests are 24. It still too many. we will take 8 tests
8/25/2011 by CJL TOD Confidential 21

Table I Factors and Levels Being Selected

Factor Stress Relief Temp Disc # per Basket Cycle Number Cycle Temp Level Low (Code: -1) 550 o F / 20 Min. 250 Per Container 2 Cycles 310 o F/10 Min Level High (Code: +1) 700 o F / 20 Min. 500 Per Container 4 Cycles 550 o F /10 Min Factor Code A B C D

StdOrder 4 1 5 6 3 7 2 8

RunOrder 1 2 3 4 5 6 7 8

SR T 1 -1 -1 1 -1 -1 1 1

Disc No 1 -1 -1 -1 1 1 -1 1

Cycle No -1 -1 1 1 -1 1 -1 1

TC Tem -1 -1 1 -1 1 -1 1 1

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22

Planned Tests
Run No SR Temp Disc No Per B Cycle No. C- Temp

1 2 3 4 5 6 7 8

550 F/20 Min 550 F/20 Min 550 F/20 Min 700 F/20 Min 700 F/20 Min 550 F/20 Min 700 F/20 Min 700 F/20 Min

250 500 250 500 250 500 250 500

2 4 4 4 2 2 4 2

310 F/10 Min 310 F/10 Min 550 F/10 Min 550 F/10 Min 550 F/10 Min 550 F/10 Min 310 F/10 Min 310 F/10 Min

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23

Test Results
Run I TFD Average Stdev Max Min Range 297.1 6.62 306.7 282.4 24.3 RUN V TFD Average Stdev Max Min Range 275.6 4.88 285.9 265.2 20.7 BFD 174.9 4.15 188.0 168.2 19.8 TFD 276.9 4.85 286.5 268.3 18.2 BFD 185.2 5.20 195.3 175.2 20.1 TFD 293.0 6.59 309.3 280.5 28.8 Run II BFD 184.0 4.95 195.3 169.3 26.0 Run III TFD 294.1 6.87 309.7 283.7 26.0 BFD 181.4 5.13 195.1 174.3 20.8 TFD 294.0 7.24 313.3 284.6 28.7 Run IV BFD 187.6 4.41 195.6 180.6 15.0

RUN VI BFD 176.5 5.40 195.8 167.7 28.1

Run VII TFD 276.8 6.85 292.8 264.4 28.4 BFD 175.5 4.35 184.2 168.8 15.4

Run VIII TFD 274.9 6.43 286.7 263.1 23.6 BFD 175.7 6.04 195.3 164.5 30.8

30 pieces of samples were taken to do stat check

8/25/2011 by CJL TOD Confidential 24

TFD Stdev
Run No 1 2 3 4 5 6 7 8
8/25/2011 by CJL

SR
o

Disc No
Pieces

TC No
Cycles

TC Temp
o

Stdev
o

550 550 550 550 700 700 700 700

250 250 500 500 250 250 500 500

TOD Confidential

2 4 2 4 2 4 2 4
25

310 550 550 310 550 310 310 550

5.28 5.48 5.12 5.99 3.58 4.09 4.81 5.58

Main Effect on The Results

Main Effects Plot (data means) for Results
5.50 5.25 5.00 SR T Disc No

Mean of Results

4.75 4.50 -1 5.50 5.25 5.00 4.75 4.50 -1 1 -1 1 Cycle No 1 -1 T C T em 1

High Temp will resulting in a lower Standard Deviation Less number of discs in a container will result in a lower Stdev Less thermal cycles will result in a lower Stdev Thermal Cycles Temp will not be of large effect

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26

Interaction
Interaction Plot (data means) for Results
-1 1 -1 1 -1 1 6 5 SR T

SR T -1 1

4 6

5 Disc No

4 6

5 Cycle No 4

TC Tem

When SR temp at high level, 250 disc discs in a container will result in a lower standard deviation When 2 cyclic number was taken with the high ST temp, it will help to reduce the stdev
8/25/2011 by CJL TOD Confidential 27

 

Cycl

 

Di

-1 1

-1 1

Analysis of Variance for Results (coded units)

Source Main Effects 2-Way Interactions Residual Error Total

DF 4 3 0 7

Seq SS 3.7040 0.8157 * 4.5197

Adj SS 3.7040 0.8157 *

Adj MS 0.9260 0.2719 *

F * *

P * *

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28

Estimated Effects and Coefficients for Results (coded units) Term Constant SR T Disc No Cycle No TC Tem SR T*Disc No Effect -0.9525 0.7675 0.5875 -0.1025 0.5925 Coef 4.9913 -0.4763 0.3837 0.2938 -0.0513 0.2963

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29

Effect of Factors
Pare to Chart of the Effe cts
(response is Results, Alpha = .05) 3.306 A B AB Term C AD D AC 0.0 0.5 1.0 1.5 2.0 Effe ct 2.5 3.0 3.5
F a ctor A B C D N ame SR T D isc N o C y cle N o T C T em

Lenth's PS E = 0.87825

Thermal Cycle Temp (D) effect is small AC and AD effect are small either
8/25/2011 by CJL TOD Confidential 30

Factorial Fit: Results versus SR T, Disc No, Cycle No After taking away the thermal temp factor:
Estimated Effects and Coefficients for Results (coded units) Term Constant SR T Disc No Cycle No SR T*Disc No Coef 4.9913 -0.9525 -0.4763 0.7675 0.3837 0.5875 0.2938 0.5925 0.2962 Effect SE Coef 0.07490 0.07490 0.07490 0.07490 0.07490 T 66.64 -6.36 5.12 3.92 3.96 P 0.000 0.008 0.014 0.029 0.029

S = 0.211847 R-Sq = 97.02% R-Sq(adj) = 93.05%

8/25/2011 by CJL TOD Confidential 31

Main Effect Factors

The main factors of the A SR Temp, B - Disc Number per container, C Number of thermal cycles
Pareto Chart of the Standardized Effects
(response is Results, Alpha = .05) 3.182
F actor A B C N ame SR T Disc N o C y cle N o

B Term AB C 0

3 4 Standardized Effect

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Residuals
Residual Plots for Results
No rmal Pro bab ilit y Plo t o f t he Residuals
99 90 50 10 1 -0.4 -0.2 0.0 Residual 0.2 0.4 Residual Percent 0.2 0.1 0.0 -0.1 -0.2 3.5 4.0 4.5 5.0 Fitted Value 5.5

Residuals Versus t he Fit t ed Values

Hist o gram o f t he Residuals

1.00 Frequency Residual -0.2 -0.1 0.0 Residual 0.1 0.2 0.75 0.50 0.25 0.00

Residuals Versus t he Order o f t h e Dat a

0.2 0.1 0.0 -0.1 -0.2 1 2 3 4 5 6 Observation Order 7 8

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Analysis of Variance for Results (coded units)

Source Main Effects 2-Way Interactions Residual Error Total

DF 3 1 3 7

Seq SS Adj SS 3.6829 3.6829 0.7021 0.7021 0.1346 0.1346 4.5197

Adj MS 1.22765 0.70211 0.04488

F P 27.35 0.011 15.64 0.029

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34

Effect Equation Obtained

= 4.9913 0.476TSR + 0.384NDisc + 0.2938NCycles +
0.296TSRNDisc Optimized Process Conditions SR Temp (TSR ) Number of Disc (NDisc) Thermal Cycles (NCycles) Thermal Cycle Temp
8/25/2011 by CJL TOD Confidential

700 o F/ 20Min 250 Pieces Per Container 2 Cycles 550 o F /20 Min
35

Confirmation Test & More Improvement

Group I Group II SR 700 F/20 Min, 250 pieces/PC ; 2 Cycles/Air Cooling, 550 F/10 Min SR 700 F/20 Min, 250 pieces/PC 2 SR ; 2 Cycles/Air Cooling, 550 F/10 Min To See if 2 times of SR will improve the Sigma SR 700 F/20Min, 250 Pieces/PC; 4 Cycles, 310F/10 Min Sorting Oil heating and Cooling SR 700 F/20Min, 250 Pieces/PC-2 SR ; 4 Cycles , 310F/10 Min Sorting Oil Heating and Cooling,

Group III

Group IV

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36

Confirmation Test Results

Test 1 TFD Averag e Stdev Max Min Range 274.30 4.03 280.30 263.30 17.00 BFD 174.17 3.81 178.50 164.40 14.10 Test 2 TFD 271.45 3.59 282.60 264.60 18.00 BFD 174.07 2.89 180.10 169.60 10.50 TFD 270.94 2.43 277.60 265.90 11.70 Test 3 BFD 173.08 2.78 177.30 166.10 11.20 TFD 271.27 3.92 282.70 263.70 19.00 Test 4 BFD 174.85 4.03 189.90 166.80 23.10

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37

Primary Metric
Sigma vs. Date
7

Objective
6

~ 4.2 o F on 7/20/05
Projected Target Actual

4 Sigma

We are here W ~ 5 o F

We have now reached: < 4

0 3/4/2005

4/3/2005

5/4/2005

6/3/2005

7/4/2005 Date

8/4/2005

9/3/2005

10/4/2005

11/3/2005

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38

Projected Parameters
S No Projected W
o

Average*
o

U S Limit
o

L S Limit
o

Z Level-U

Z Level-L

PPM-U

PPM-L

PPM-T

Yield

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

6.50 6.00 5.50 5.00 4.50 4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50

275.0 275.0 275.0 275.0 275.0 275.0 275.0 275.0 275.0 275.0 275.0 275.0 275.0

268.0 268.0 268.0 268.0 268.0 268.0 268.0 268.0 268.0 268.0 268.0 268.0 268.0

When 1st

278.0

< 4 o F,
0.46 0.50 0.55 0.60 0.67 0.75 0.86 1.00 1.20 1.50 2.00 3.00 6.00

1.08 1.17 1.27 1.40 1.56 1.75 2.00 2.33 2.80 3.50 4.67 7.00 14.00

322206 308538 292720 274253 252492 226627 195683 158655 115070 66807 22750 1350 0

140757 121673 101557 80757 59907 40059 22750 9815 2555 233 2 0 0

462964 430210 394278 355010 312399 266686 218433 168471 117625 67040 22752 1350 0

53.70 56.98 60.57 64.50 68.76 73.33 78.16 83.15 88.24 93.30 97.72 99.87 100.00

278.0 278.0 278.0 278.0 278.0 278.0 278.0 278.0 278.0 278.0 278.0 278.0

sorting Yield will be ~ 75%

* Normal Center is 273 F, It is allowed the actual center control between 272 and 275 o F

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39

Conclusions
By Optimizing the Stability Conditions as below:
SR 700 o F / 20 Min. 250 pieces/Per Condition 2 Thermal Cycle with temp as 550 o F /10 Min.

It is able to improve the performance:

The first Sorting yield increased from 50 % to 75% The final yield will be more than 80%.

This corresponds to an approx labor saving of 4000 hrs. The 10% yield improvement corresponds to a cost reduction of approx. $80,000 per year. ( 4 million discs per year in production )
8/25/2011 by CJL TOD Confidential 40

Future Works
Effect of the blank number on the Forming Effect of Punch Spherical Radius on the Forming Second Phase Improvement Target: 10-15% improvement
TFD Stdev Target should be < 1.75 o F

Third Phase Improvement Long Run Maximum is about 19.9 % of improvement

TFD Stdev Target should be < 1 o F
8/25/2011 by CJL TOD Confidential 41