1. Project: Downtime Reduction Date Opened: October 30, 200x
I&CIM Contact: Jim Altier
Customer: Users
Project Sponsor: Superintendent
Project status: Control and Maintain
Problem Definition
Department, Area, 30% of all
maintenance downtime due to process related calls.
Print requirement for process is:
“Present on the mating interface area
and on the outside of the core crimp wings”.
Project Scope
Reduction in process calls and faults due to an inconsistent
process.
Goal is an 80% reduction in faults and calls as well as associated
scrap generated by start stop and 25% reduction in overtime.
Implement Improvements
Control and Maintain
Characterize Current State/ID failure modes
Current State:
process is applied to the parts via Central Lube System,
pressurized source. The oil is applied post stamping process and
pre-reeling.
A presence detection system that verifies the presence of oil in the
contact areas of each terminal type (male / female), is in place.
40% of maintenance calls due to process (70% PF & 24% EL).
Failure modes:
Inconsistent sensing at the current levels of process application.
Process capability currently at Cpk & 2.6 Sigma.
All presses changed to reflect the values
determined by experimentation
during the project.
Engineering developed a
troubleshooting guide for the
trades, supervisors, technicians
and operators in determine settings
and changes in the process during operation.
Based on data from the SEM the low level of process was changed from 250 units to 150.
Gage R&R performed on the sensor, the sensor is capable of distinguishing various levels of process from part to part.
Capability was improved to 4.1 Sigma from 2.6 and Cpk to 1.39 from
process related downtime (hours) has been reduced from an average 638 hrs. a month to 212, a 68% improvement, faults were 8.4% of the total, now 2.6%, a 69% improvement. Start/Stop scrap reduced by 69%, a $17, savings, process related maintenance calls were 30% of all calls, now 12% , a 60% improvement.
Sigma Level =
USL = 650 / LSL = 250
Cpk = .8708
DPM = 4,510
Faults 75
150
225
300
375
450
525
600
675
750
Jun-02
Jul-02
Aug-02
Sep-02
Oct-02
Nov-02
Month
# of Faults
process
All
40%
USL = 650 / LSL = 150
Sigma Level =
Cpk =
DPM = 22.0 25 50
100
125
175
200
250
275
325
350
Dec-02
Jan-03
Feb-03
Mar-03
# of Calls
74% reduction
Changes made to machine logic regarding high & low fault points (3/21/03)
SEM Analysis
Evidence that process is present at low reading.
Pipe fitter calls have reduced gradually since the beginning of the project. Partially due to the attention placed on the problem and education during the improvement phase.

2. DEFINE Six Sigma Project Team: Black-Belt: Jim Altier Green Belt
Candidates:
Project Sponsor:
Project Champions(s):
Master Black-Belt:
Problem Statement and Background
Plant X, department x currently produces the GT Terminal family, the terminal print requires a presence of process on
all parts. process is a silicone fluid used to enhance the conductivity of the connection. A by-product of process is that
it aids in crimping, therefore, it is required on the back side of the core crimp wings. The print defines the amount of
process with a spray rate of .75 gallons per million parts and present in the mating interface and on the outside of
the core crimp wings.
process is supplied by vendor at a cost of $ per gallon. vendor does not produce the silicone fluid, they merely mix a UV
tracer in and distribute. The tracer is used for sensing only.
Current process application and sensing process accounts for 30% of all maintenance downtime in Plant X, department x.
The process is post stamping and applied via a pressurized source with a reclaim system for the excess fluid. The sensing
equipment works entirely off of the UV tracer through a sensor. This instrument is used to detect the
luminescent properties of the process material. The visible light is received and converted to an analog signal that is tied
to the stamping press. If the process level falls below or above the preset limits of the sensor the press will fault out and
shutdown. Various terminal parts numbers are start stop sensitive and generate scrap reels every time the press shuts
down. At this time the data from the sensor is averaged every 225 readings and compared to the preset limits, which
are 250 to Once 6 consecutive readings fall out of the range the press faults and shuts down.
process related downtime is equivalent to 1 hour down time for every 8 hours of run time. The goal of the project team is to
reduce downtime and related scrap by 80%. An 80% reduction will increase capacity by 1,000,000 parts. The
increased capacity will be used to reduce overtime by 25% which is worth $40, and a scrap savings of $20,
DEFINE

3. DEFINE
Data collected from the maintenance dispatch system.

4. DEFINE / MEASURE

5. ANALYZE

6. ANALYZE

7. Prior to Improvements ANALYZE Cpk Analysis Long Term Short Term
Mean =
Cpk Analysis
Mean =
StdDev =
StdDev =
USL = 650
USL = 650
LSL = 250
LSL = 250
Sigma Level =
Sigma Level =
Sigma Capability =
Sigma Capability =
Cpk = .8708
Cpk = .9509
Cp =
Cp =
DPM = 4,510
DPM = 2,170
N = 209
N = 209
ANALYZE
In spec
Out spec left
Out spec right
LSL
USL
Short Term
139
152
166
179
192
205
219
232
245
258
272
285
298
311
325
338
351
364
378
391
404
417
431
444
457
470
484
497
510
523
537
550
563
576
590
603
616
629
643
656

8. After Improvements IMPROVE Cpk Analysis Long Term Short Term
Mean =
Cpk Analysis
Mean =
StdDev =
StdDev =
USL = 650
USL = 650
LSL = 150
LSL = 150
Sigma Level =
Sigma Level =
Sigma Capability =
Sigma Capability =
Cpk =
Cpk =
Cp =
Cp =
DPM = 22.0
DPM = 3.613
N = 209
N = 209
IMPROVE
In spec
Out spec left
Out spec right
LSL
USL
Short Term
139
153
167
181
196
210
224
238
252
266
280
294
309
323
337
351
365
379
393
408
422
436
450
464
478
492
507
521
535
549
563
577
591
605
620
634
648
662

9. IMPROVE

10. IMPROVE

11. CONTROL

12. Sigma Level = 4.1903 / Sigma Capability = 4.2517
Mean = / StdDev =
USL = 650 / LSL = 150
Sigma Level = / Sigma Capability =
Cpk = / Cp =
DPM = 22.0 / N = 209