1 High Volume Material Distribution System (Project ID: xxxxx ) March 14, 200x

Delphi Confidential2 D1: Charter Team Date: September 28,200x Project Team Leader(s): Project Champion (s): Team Members: Project Sponsor: Project Title:High Volume Material Distribution System (Project ID: xxxxx ) Project Details: When presses, requiring the high volume materials, need material they send a signal to the Central Distribution System which in turn sends the material through the feed system pipes to the press. As more presses came on line in plant XX we’ve noticed that presses, running high volume material, on several lines began shutting down due to lack of material. As more tools are in-sourced there is the potential that this condition will only worsen and be widespread throughout the plant. Business Case addressed : Improve Machine Uptime. Key Deliverables: (Dates) Define: Sept/Oct. 200xMeasure: October 200xAnalyze: November 200xImprove: January 200x Control:February 200x Critical Milestones: Determine root cause of downtime caused by the material distribution system. Customers/ Suppliers who must be involved: Plant Manufacturing, Engineering, and PC&L “Must-Dos” in terms of Project scope: Identify causes of material flow problems. Things definitely not in the project scope: Uptime issues other than material. How the Project will be Measured: Machine Uptime. Jim Altier Champion(s) Deployment Champion Sponsor Master Blackbelt Green belts Finance (signatures to initiate project) Champion(s) Deployment Champion Sponsor Master Blackbelt Green belts Finance (signatures to close project)

Delphi Confidential3 D2: Scope Project

Delphi Confidential4 D2: Scope Project

Delphi Confidential5 D3: Identify Customers and Requirements When presses, requiring the high volume materials, need material they send a signal to the Central Distribution System which in turn sends the material through the feed system pipes to the press. As more presses came on line in plant xx we’ve noticed that presses, running high volume material, on several lines began shutting down due to lack of material. As more tools are in-sourced there is the potential that this condition will only worsen and be widespread throughout the plant.

Delphi Confidential6 M1: Identify Project Measure (Y)

Delphi Confidential7 M1: Identify Project Measure (Y) Characteristic – Availability Operational Definition – Any time a machine is down because the material delivery cannot fill the demand. Target – 0 downtime Specifications – Defect Definition – Any downtime Name for the Measure – Machine down due to lack of material

Delphi Confidential8 M1: Identify Project Measure (Y)

Delphi Confidential9 M2: Data Collection Plan Screen shot of a model develop by xxxxx xxxxx to better understand the workings of the system (vacuum) by modeling the variables. Model developed in excel and copied into a access database currently being used.

Delphi Confidential10 M2: Data Collection Plan Two different studies were conducted to determine the effects of material type and distance of the press from the central system on material flow rates. The first study measures the amount of material conveyed, based on the average of 3 loads of 4 seconds each, to the closest (xxx) and furthest (xxx) press form Region 1 on line 5. Seven different materials were conveyed to each press. The second study measured the amount of material conveyed to each of the 15 presses for a single 6 second load from Dxx (PAxxxxx – Blended Black).

Delphi Confidential11 M2: Data Collection Plan Study 1: The purpose of this study was to determine the effects of distance and material type on the flow rate per second of load time. Results: Distance does not affect the amount of material conveyed for a given load time. Only the purge time needs to vary based on the distance the material is conveyed. Since the load time is the amount of time the material valve is open at the regional hopper allowing the flow of material into the vacuum stream it makes sense that the distance of the destination press would not have any affect on this process. The purge time would be affected because of the greater distance the material needs to be moved and the additional pipe that would need to be cleared as the distance is increased. The obvious outcome of the study is that the hopper takeoff probes are not properly adjusted for maximum flow. If the results of conveying from DH9, DH13, DH16 and DH2 to any single press are compared it is evident that DH9 has been optimized as it is the furthest away yet flowed more than twice the amount of material per second. The above group of hoppers all contain the same nylon 66 material. The study does not show a correlation between material type or specific gravity of the material and flow rate, though this is known to have a significant effect. This is most likely being masked by the maladjustment of the takeoff probes.

Delphi Confidential12 A2: Root Cause Analysis Study 2: The purpose of this study was to verify the result in study 1 that distance does not affect load time, but only the purge time of the conveyance cycle. Results: The results of conveying the same material from DH9 to each of the machines for 6 seconds on line 5 confirms that distance does not have a significant affect on amount of material conveyed per second of load time (blue line). The data points and trend lines (black line) are not as expected though. The data should trend slightly up from right to left in a linear fashion (red line). This would reflect the slight variation in conveyance between the closest and furthest press. The data indicates a problem, or sag, conveying to the presses in the middle of the bank. These are also the largest machines which would compound capacity issues as they require more material throughput. These machines were also retrofitted with larger shot loaders which may be the source of the variation, not due to the size, but possibly due to the design or fit causing leakage issues. Further investigation will be required.

Delphi Confidential13 A2: Root Cause Analysis The collective average ounces of material conveyed per second for all materials tested were 7.5. The range for the seven hoppers tested was between 3.9 and 16.9 ounces per second. These numbers were generated measuring 3 consecutive shots of each material for a four second load time. The large range in flow rate results indicates issues with the takeoff box ratio adjustments. Some of the variation could be contributed to differences in materials and fillers, but there are also large differences between same materials that only vary in color. Adjustments need to be made to the takeoff ratios during a shutdown period and further studies conducted to establish a new average flow rate to be used in the simulation calculations. Max possible Lag as material is fluidized into the vacuum stream The expected average, or theoretical flow rates, of unfilled material from an optimized hopper and takeoff box should be in the 15 to 20 ounces per second range. Glass filled material will be somewhat less due to the higher specific gravity and tendency to of the material pack.

Delphi Confidential14 A2: Root Cause Analysis Data indicates that we have 2 root causes that need action: 1.Load and purge settings: Need to be optimized. 2.Conveyance of material: Hoppers need work. Roadblocks: Need machine downtime for Hoppers and need a plan for Load and Purge settings.

Delphi Confidential15 I1: Develop Solutions  The previous study indicated that material conveyance was the factor that needed addressed before other changes could have an impact.  During Independence week shutdown hoppers were re- worked to resolve conveyance issues.  The next slides will cover that data that was collected after the changes were made.

Delphi Confidential16 I2: Test Solutions

Delphi Confidential17 I2: Test Solutions

Delphi Confidential18 C1: Implement Solution Central Material System Take off Box Adjustment The material take off box at the bottom of the regional material hoppers in the plant xx have a pipe within a pipe configuration. The inner pipe has an oval hole which is the material feed to the mold machines. This pipe can be adjusted by removing the 4 bolts on the outside of the take off box at the bottom of the material hopper. Once the bolts are off the pipe can be turnedclockwise or counter clockwise until the boltholes line up again. So youu can position the holein relation to how the material enters into the tube. Typically the hole faces straight down when it comes from the factory. This is fine for low density materials such as polypro but when you are trying to run glass filled nylon you may have a problem. This is because the vacuum has to lift the material into the pipe so it can be fed into the machine. The greater the density the harder it is to feedthe material into the pipe. By turning the inside pipe such that the hole is positioned slightly upward allows the material to feed directly into the pipe. Now the vacuum pump does not have to lift the material to get into the pipe and eventually to the mold machine.

Delphi Confidential19 C1: Implement Solution

Delphi Confidential20 C2: Assess Capability Material in ounces 7.5 (before) (after) Pump Capacity used (before) Pump Capacity used (after) Lines 1&2124.9%41.3% Lines 5&6147.6%48.8%

Delphi Confidential21 C3: Close Project Engineering estimated a $150, savings due to avoidance of addition vacuum equipment and installation.