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12/21/00 1 Team: SafeKrackers Associate Name AddressPosition Tracy D. Hille Sr. Program Engr. George Pucci.

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Presentation on theme: "12/21/00 1 Team: SafeKrackers Associate Name AddressPosition Tracy D. Hille Sr. Program Engr. George Pucci."— Presentation transcript:

1 12/21/00 1 Team: SafeKrackers Associate NameE-Mail AddressPosition Tracy D. Hille tracyh@epicturbo.com Sr. Program Engr. tracyh@epicturbo.com George Pucci gpucci@lear.com Facilities Mgr. gpucci@lear.com Mike Wheeler mwheeler@wollin.com Process Engr. mwheeler@wollin.com John Reddaway John.reddaway@tenneco-automotive.com Tech. Support Engr. John.reddaway@tenneco-automotive.com Tim McIlrath Tim.mcilrath@tenneco-automotive.com Sr. Design Engr. Tim.mcilrath@tenneco-automotive.com Eric Everman eeverman@lear.com Q.A. Engr. eeverman@lear.com Manufacturing 327 Phase II Slides will advance automatically

2 12/21/00 2 Problem Statement The number one field failure is related to the servo drive shaft coupler that connects the programmable servomotor to the vault combination knob.The number one field failure is related to the servo drive shaft coupler that connects the programmable servomotor to the vault combination knob.

3 12/21/00 3 Project Objective 1.Develop Core Team. 2.Analyze Field Failures. 3.Determine Defective Coupler Cause. 4.Reevaluate Coupling Design. 5.Cost Analysis of Redesigned Coupling. 6.Implementation of New Couplings.

4 12/21/00 4 Performance – Pareto Chart

5 12/21/00 5 Finite Element Analysis - FEA TensionTorsion

6 12/21/00 6 FEA – Red Stress Areas TensionTorsion

7 12/21/00 7 Irreversible Corrective Action 1.Maintain Correct Rib Thickness (SPC Analysis Performed On-Line). 2.Radius Relief End of Each Slot (CNC Program Enhanced).

8 12/21/00 8 Corrective Action Cost Analysis 1.Cycle Time - Original5.04 minutes = $2.21 - Original5.04 minutes = $2.21 - New5.34 minutes = $2.34 2.Add SPC Analysis. 3.Reduce Cutter Life 4.Scale Back Final Torque Test from 100% to AQL.

9 12/21/00 9 How To - Long Form SafeKrackers Long Form is broken down into four sections: 1 – Introduction 2 – Appendix A (SDA’s) 3 – Appendix B (RCA’s) 4 – Bibliography

10 12/21/00 10 Long Form - Introduction The Introduction has links imbedded into the document. Simply mouse click on a blue link to jump to the corresponding form in the appendix. Press the blue arrow at the top of the page to jump back to the introduction.

11 12/21/00 11 The introduction details overviews of the Company, Customer, Product, Quality, and Process. It also details the Slot Cutting Process, along with Additional Process Improvements. Long Form - Introduction

12 12/21/00 12 This section includes all forms used during the objective of the project. These are referred to as Standard Dedicated Applications – SDA’s You will find them in the following order: Safety, Quality, Process, Finance, Planning. Long Form – Appendix A

13 12/21/00 13 This section includes additional information gathered during the project. These are referred to as Regular Critique Assignments – RCA’s. RCA’s include: additional reading sources, team assessments, rotational matrix, and management review. Long Form – Appendix B

14 12/21/00 14 This section details all sources used during the project. Long Form – Bibliography

15 12/21/00 15 Company Goal Advance Relentlessly


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