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 .8708 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 .8708. 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 $17,000.00 savings, process related maintenance calls were 30% of all calls, now 12% , a 60% improvement. Sigma Level = 2.6123 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 = 4.1903 Cpk = 1.3968 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.

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 $355.00 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 650. 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 $40,000.00 and a scrap savings of $20,000.00. DEFINE

DEFINE Data collected from the maintenance dispatch system.

DEFINE / MEASURE

ANALYZE

ANALYZE

Prior to Improvements ANALYZE Cpk Analysis Long Term Short Term Mean = 403.608 Cpk Analysis Mean = 403.608 StdDev = 58.801 StdDev = 53.848 USL = 650 USL = 650 LSL = 250 LSL = 250 Sigma Level = 2.6123 Sigma Level = 2.8526 Sigma Capability = 3.4013 Sigma Capability = 3.7142 Cpk = .8708 Cpk = .9509 Cp = 1.1338 Cp = 1.2381 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

After Improvements IMPROVE Cpk Analysis Long Term Short Term Mean = 403.608 Cpk Analysis Mean = 403.608 StdDev = 58.801 StdDev = 53.848 USL = 650 USL = 650 LSL = 150 LSL = 150 Sigma Level = 4.1903 Sigma Level = 4.5757 Sigma Capability = 4.2517 Sigma Capability = 4.6427 Cpk = 1.3968 Cpk = 1.5252 Cp = 1.4172 Cp = 1.5476 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

IMPROVE

IMPROVE

CONTROL

Sigma Level = 4.1903 / Sigma Capability = 4.2517 Mean = 403.608 / StdDev = 58.801 USL = 650 / LSL = 150 Sigma Level = 4.1903 / Sigma Capability = 4.2517 Cpk = 1.3968 / Cp = 1.4172 DPM = 22.0 / N = 209