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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
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
8/25/2011 by CJL
TOD Confidential
Primary Metric
Sigma vs. Date
7 6
4 Sigma
~ 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
8/25/2011 by CJL
TOD Confidential
VA
Cleaning CL-355 & BF-603
VA
VA
VA
Deburring TM-701 & BF-605
VA
DPU Stress Relief SR 103
VA
1st
VA
8/25/2011 by CJL
TOD Confidential
10
VA
VA
VA
Yes VA Cleaning CL - 355 Dock Audit BF-609 Inspection Audit QCW B1425
Package Shipment RFU Style No 46338
8/25/2011 by CJL
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
99.99
99.95
C C C
VA
Visual Checking
CL-355
0.002 45 Min
99.8
CR C C C C C
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
5E-04 45 Min
99.95
Total
0.054 3 Days
94.6
8/25/2011 by CJL
TOD Confidential
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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
2
Cleaning Oil or contamination present
3 2
Contact maintenan ce
3
Deburring
Vibration time too short Punch tool is dull resulting in too much burr Disc equipment tooling wear.
1 0
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
8/25/2011 by CJL
TOD Confidential
Heat Treatment
Too high Temp, EQ. Out of Control Too Low Temp, EQ out of Control
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
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
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
8/25/2011 by CJL
TOD Confidential
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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
8/25/2011 by CJL
TOD Confidential
18
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
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
8/25/2011 by CJL
TOD Confidential
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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
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
8/25/2011 by CJL
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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 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
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
2 4 2 4 2 4 2 4
25
Mean of Results
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
8/25/2011 by CJL
TOD Confidential
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
DF 4 3 0 7
F * *
P * *
8/25/2011 by CJL
TOD Confidential
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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
8/25/2011 by CJL
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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
B Term AB C 0
3 4 Standardized Effect
8/25/2011 by CJL
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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
8/25/2011 by CJL
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DF 3 1 3 7
8/25/2011 by CJL
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700 o F/ 20Min 250 Pieces Per Container 2 Cycles 550 o F /20 Min
35
Group III
Group IV
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8/25/2011 by CJL
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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
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
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
* Normal Center is 273 F, It is allowed the actual center control between 272 and 275 o F
8/25/2011 by CJL
TOD Confidential
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.
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