1. Application of Quality Improvement Techniques to the Powder Coat Process
Joan Burtner, Chris Durre & Nikki Smith
Department of Mechanical and Industrial Engineering
Mercer University, Macon, GA

2. The Six Sigma Approach in the Business Community
Six Sigma - a comprehensive system for achieving, sustaining and maximizing business success
Drivers
a close understanding of customer needs,
disciplined use of facts, data, and statistical analysis
diligent attention to managing, improving, and reinventing the business process
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

3. Benefits of the Six Sigma Approach
cost reduction
productivity improvement
market-share growth
customer retention
cycle-time reduction
defect reduction
culture change
product/service development
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

4. The Six Sigma Philosophy
Designed to foster data-driven management decisions
The Three C’s
common metrics
“constant” communication
culture change
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

5. Selection Criteria for Six Sigma Improvement Projects
There is a gap between current and desired/needed performance.
The cause of the problem is not clearly understood.
The solution isn’t predetermined, nor is the optimal solution apparent.
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

6. School of Engineering Senior Design Course
Two semester course required for graduation with a bachelor’s degree in engineering or industrial management
Student Teams
Two or three students
Often interdisciplinary
Management
Senior design course instructor
Departmental technical advisor
Client – internal or external
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

7. Presenter: Dr. Joan Burtner, Mercer University
Paint Cell Project
Interdisciplinary team
Industrial management
Industrial engineering
Technical advisor - Joan Burtner
External client
Georgia manufacturer
Practices Six Sigma philosophy
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

8. Powder Coat Process Overview
Material - powdered paint
Two basic application methods
Part is lowered into a fluidized bed of the powder, which is electrostatically charged
Powdered paint is electrostatically charged and sprayed onto the part
Curing
Part placed in an oven - powder particles melt and form a continuous film
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

9. Presenter: Dr. Joan Burtner, Mercer University
Powder Coat Equipment
Spray Gun
Corona charging guns -electric power used to generate the electrostatic charge
Tribot charging guns - electrostatic charge generated by friction between the powder and the gun barrel
“Bell” charging guns -powder charged by being "flung" from the perimeter of the "bell
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

10. Powder Coat Facility Typical Spray Booth
Courtesy:
Accessed March 12, 2004
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

11. Presenter: Dr. Joan Burtner, Mercer University
Quality Issues
Surface preparation
Operators
Training
Skill
Coverage
Color change
Cleanliness/ contamination
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

12. Presenter: Dr. Joan Burtner, Mercer University
Six Sigma Methodology
Define
Measure
Analyze
Improve
Control
Project Scope D-M-A
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

13. Preliminary Process Map
Load
Wash
Dry
Paint
Cure
Rework
Accept
Unload
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

14. Paint Cell Process Matrix
Process Step #
Input
Measure System
C/U
Type
Output
Load 4
Wash
Dry 2
Drying oven
Visual inspection C
Dry panel
Paint 6
Cure
Unload 1
Rework
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

15. Key Customer Requirements
Minimal paint thickness
Even coverage
Scratch-free parts
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

16. Preliminary Data Collection
Student teams
Observer
Recorder
Random sampling
75 observations for control charts
Collection sheet variables determined by client
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

17. Revised Data Collection
Student teams
Observer – voltage, temperature, etc
Thickness gauge operator
Thickness gauge recorder
Revised data collection form
Limited variables – panel, color, hook, 5 locations
Larger cells for recording data
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

18. Cause and Effect Matrix#
Process Step
Process
Input
Paint
Thickness
Even
Coverage
Damage
Free
Total
Customer Imp 7
Customer Imp 9
Customer Imp 10 1
Load
Hook 3* 3
78** 2
Conveyor 78
Spray Gun 9
154 4
Cure
Temp 58
* Correlation values 0, 1, 3, **Sample calculation 7*3+9*3+10*3=78
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

19. Control Charting Deliverables
Target Factor - paint thickness
Data collection plan
Documentation of plan as standard operating procedure
Control chart training materials
Control charts of baseline data
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

20. Control Charting Locations
Factor - paint thickness
5 locations
Repeated measures
25 samples for baseline chart
North
West Middle East
South
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

21. Control Charting Sample Preliminary
Range not in control
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

22. Control Charting Sample Results - Revised
Range in control Xbar not in control
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

23. Presenter: Dr. Joan Burtner, Mercer University
Designed Experiments
Dependent variable - paint thickness
Factor 1 - location
Factor 2 - shift
Statistical software package - Minitab
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

24. Failure Modes and Effects Analysis (FMEA) Techniques
48 process steps selected for investigation
4 experts polled
Operators
Management
Ratings entered into basic FMEA worksheet
RPNs calculated
Process steps ranked by RPN (high to low)
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

25. Failure Modes and Effects Analysis - Category Ratings 1
Severity of Effect (10-1)
Hazardous without warning
Hazardous with warning
Loss of primary function
Reduced primary function performance
Loss of secondary function
Reduced secondary function performance
Minor defect noticed by most customers
Minor defect noticed by some customers
Minor defect noticed by discriminating customers
No effect
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

26. Failure Modes and Effects Analysis - Category Ratings 2
Likelihood of Occurrence
9 Very High: Almost inevitable
7 High: repeated failures
4 Moderate: Occasional failures
2 Low: Relatively few failures
1 Remote: Failure is unlikely
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

27. Failure Modes and Effects Analysis - Category Ratings 3
Ability to Detect (10-1)
Cannot detect
Very remote chance of detection
Remote chance of detection
Very low chance of detection
Low chance of detection
Moderately high chance of detection
High chance of detection
Very high chance of detection
Almost certain detection
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

28. Risk Priority Number Example Calculations
Paint Material – accident or transport failure
Potential Failure Effect
Lack of paint consistency
Severity of Effect rating 4
Potential Cause
Dropped powder
Likelihood of Occurrence rating 3
Current Control
Lifting procedures
Ability to Detect rating 3
Severity*Likelihood*Detection = 36 = RPN
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

29. Failure Modes and Effects Analysis Results
Ratings ranged from 300s to 20s
Uncontrolled process steps eliminated
Critical controlled process steps
Powder application - operator
Cure process
Powder application - spray gun
Loading
Unloading
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

30. Control Plan Worksheet
Critical to Quality (CTQs) factors listed according to RPN ranking
Process step as listed in process map
Inputs/outputs
Process specifications
Measurement system
Current control plan
Control method
Who
Where
When
Reaction plan
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

31. Control Plan Follow-up
Revision of current standard operating procedures (SOP)
Establishment of standard operating procedures for CTQs that do not already have an SOP
Periodic review
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

32. Presenter: Dr. Joan Burtner, Mercer University
Future Work
Phase 1
Development of plan for constant metrics
Implementation of new SOPs
Phase 2
Periodic process review
Implementation of new metrics as needed
Phase 3
Project closure
Implementation of related Six Sigma projects
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University

33. Presenter: Dr. Joan Burtner, Mercer University
Contact Information
Room 105D, School of Engineering
Phone (478)
Fax (478)
IIE Annual Conference May 2004
Presenter: Dr. Joan Burtner, Mercer University