1. AP4/5 Lean Manufacturing Team April 26, 2004 AP5 Lean Manufacturing Broken Capillary Tubes e Team Members: Blake Samic Brent Adams Dan Healy Chris Kantus Chad Linville Aaron Frees Advocacy Team: Kyle Minnick - Mentor Thiago Tognetti- Mentor Rob Willy - Mentor

2. AP4/5 Lean Manufacturing Team April 26, 2004 AP5 Lean Manufacturing Broken Capillary Tubes e AP5 Capillary Tube Scrap Reduction

3. AP4/5 Lean Manufacturing Team April 26, 2004 AP5 Lean Manufacturing Broken Capillary Tubes e Problem Area Outside Case Inside Case Refrigerator Smaller capillary tube is still clearly attached to the large tube assembly. Capillary tube is no longer visible outside of the case, indicating that it has been broken off at the entrance to the cas.

4. AP4/5 Lean Manufacturing Team April 26, 2004 AP5 Lean Manufacturing Broken Capillary Tubes e Possible Root Causes Excessive bending of capillary tube during production Many stations bend tube multiple times May strain material, causing breakage further down the line Missing/Misplaced protective tape on tube Unprotected tube rubs on raw edge of case back Rubbing may score tube, causing breakage Reuse of salvaged capillary tube assemblies Rerun tube undergoes more bending than normal Holes in assembly at liner drop Capillary can become hung up in holes causing severe scoring of the capillary tube

5. AP4/5 Lean Manufacturing Team April 26, 2004 AP5 Lean Manufacturing Broken Capillary Tubes e Testing and Packaging Process Flow Capillary Tube is attached to the formed plastic liner. Case Line Capillary Tube from Supplier Repair Assembly Freezer Liner Formation Plastic liner to which cap tube will be assembled is formed. Tube arrives from outsourced supplier. Capillary Tube is attached to the formed plastic liner. Capillary Tube is foamed into the finished case making it impossible to easily replace. Ends of capillary tube assembly are brazed to the evaporator and hi side assembly. Somewhere in assmebly the broken capillary tube is identified by a worker and marked out for repair. Refrigerators are scrapped at repair and never make it to test and pack. Possible poor tube design identified by PMQ could be contributing to broken tubes. Hole in conveyor identified as definite contributor to broken tubes. Reuse of capillary tubes of scrapped freezer liners identified as possible secondary cause. Reused tubes are currently being tagged to help identify whether this is a contributor to the issue.

6. AP4/5 Lean Manufacturing Team April 26, 2004 AP5 Lean Manufacturing Broken Capillary Tubes e Financial / Business Benefits Soft Benefits Labor reduction Less rework and salvage time with scrapped units Fewer salvaged parts returned to line Hard Benefits Elimination of 3 or more scrapped units per week ($45,000/Yr) Elimination of 3 scrapped units per week ($45,000/Yr) Labor reduction Less rework and salvage time with scrapped units Fewer salvaged parts returned to the line

7. AP4/5 Lean Manufacturing Team April 26, 2004 AP5 Lean Manufacturing Broken Capillary Tubes e Actions Note: After covering the hole on the assembly line no broken capillary tubes were seen for a week and a half. A few were seen at the end of last week but we are unsure if these breaks are caused by the same one that has been causing the three or so a week. None of the units with broken tubes have yet to be from a rerun tube off of a bad liner. Identified hole in the case assembly line were capillary tubes were becoming snagged and scored. Hole was temporarily covered by Case Line BTL Kyle Minnick and in long term the hole will be permantently bolted shut. All rerun capillary tubes off of scrapped liners are being marked in or to discern whether the rerunning of these tubes is contributing to the issue

8. AP4/5 Lean Manufacturing Team April 26, 2004 AP5 Lean Manufacturing Broken Capillary Tubes e Current: On average 3 or more completed units per week are scrapped because of broken capillary tubes. Future: Plan to place metal slugs into assembly line to cover any and all holes where tube may become caught. No reuse of capillary tubes (if long term results indicate that this contributes to problem. 3 units a week are scrapped due to broken capillary tubes with costing the business $45,000 annually Place metal slugs in all holes on assembly line where the capillary tube may hang up Possibility of not rerunning capillary tubes off of scrapped liners

9. AP4/5 Lean Manufacturing Team April 26, 2004 AP5 Lean Manufacturing Broken Capillary Tubes e Capillary Tube Project Contacts Jay Fields (BTL Case Line) Kyle Minnick (BTL Case Line) Gene Pikes (Tech Support Case) Martin Pike (Inspector Assembly Line) Larry Byrne (EOLA Technician) Larry Crouch (Test and Pack Repairman) Mike Mulcahy (BTL Case Line) Del Cofield (Blackbelt AP4/5)

10. AP4/5 Lean Manufacturing Team April 26, 2004 AP5 Lean Manufacturing Broken Capillary Tubes e What we gained from our lean experience C communicate with individuals out on the floor to work towards a common goal to research an issue of which we had no prior knowledge how to formulate a plan of attack in order to solve the issue work together with teammates on a project that would otherwise be to large and time consuming to u undertake alone. We learned how to: We learned never to: start investigating an area in a union factory without first consulting the union steward. take pictures of any union personel on the job. n ever to bring a camera, stopwatch, or large group of engineers into an area and start asking questions without first having the proper meetings with union officials.