seg ncu-arnab marik
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Slide 1
Reduce SEG NCU
ARNAB MARIK& Team
21st JAN 2015
Revision 11/29/01
Slide 2
D M A I C
Project CharterREF REF
1 12
REF TASK/Milestone june july aug sept oct nov-dec REF Team Member RoleD Define Phase 1 Kiran Kumar SponsorerM Measure Phase 2 Sakthivel E2A Analyse 3 Arnab Marik GET, LeaderI Improve Phase 4 IM Rao SME
C Control Phase 5 Naresh Behera SMEProject Closure 6 Satish Member
7 Soumitra/Avishrant Financial Controller8 VK Singh Member
PROJECT PLAN TEAM SELECTION
GOAL STATEMENT
50% reduction in Assembly rejects (from 16% to 8%)50% reduction in SEG NCU rejection (from 17 % to 8.5%)
PROJECT SCOPERoller Cell - Line 1 & 2 & 4 & 6
Slide 3
D M A I C
Sl What we have measured What Lean Six sigma tools used
Objective
1 Base line process KPIBase line process KPI IR chart IR chart Track the KPI progressTrack the KPI progress
2 Root Cause for SEG NCU Root Cause for SEG NCU and Shallow Recessand Shallow Recess
Cause and Effect Cause and Effect DiagramDiagram
Grouping of Ideas into Grouping of Ideas into logical categorieslogical categories
3 Study one part no. 502 and Study one part no. 502 and analyze.analyze.
IR ChartIR Chart Tracking of the SEG Tracking of the SEG NCU.NCU.
4 Assly rejectsAssly rejects Kappa StudyKappa Study Study Concurrence Study Concurrence between off line and between off line and roller inspectorsroller inspectors
5
Define and Measure - ApproachDefine and Measure - Approach
Slide 4
D M A I C
KPI DetailsGoal Statement : Reduce SEG NCU rejects by 50%
(from 17% to 8.5%)Reduce Assembly rejects by 50%(from 15.5% to 8%)
KPI : SEG Rejects in %age
KPI target details : Base Period – Sept’14 to Mar’15KPI value- Rs.6 L
Target completion date – jan’16
Slide 5
D M A I C
Cause&Effect Matrix
MACHINE & TOOLS
SEG spindle
Condition of SEG tooling – guide plate and G/W collet M/C
qualification
G/W radius
MATERIAL
Raw material quality from Header
Excess Grease in Wire
Damage from H/T
SEG NCU
Machine Set up – Header and SEG
MAN
Operator skill
Tool Inspection
Adherence to SOP
MEASUREMENT
Knowledge of Visual Standard
Slide 6
D M A I C
Base Line (roller reject)
10.0
12.5
15.0
17.5
20.0
22.5
25.0
SEG
Rej
ect a
s %
of T
otal
Pro
duct
ion
1 2 3 4 5 6 7 8 9 10 11 12Sample
Avg=17.121
LCL=11.388
UCL=22.855
Individual Measurement of SEG Reject as % of Total Production
Control Chart
Target – 8.5%
Slide 7
D M A I C
Main Causes of SEG NCU
•Heading Defect.
•Roller Recess Depth.
•Diamond Set Up and Pressure Head set up at SEG.
•Empty Disc.
•Size variation from Constant Stock.
•Conflict in the understanding of Max passable rollers between off-line inspectors and roller inspectors.
Slide 8
D M A I C
SEG NCU Study of 502Off Centre at Header resulting in NCU after Grind
Slide 9
D M A I C
SEG NCU StudyMain Reasons for heading defect (off centre) –
1. Alignment problem or off centre between head punch and FOP.
2. Punch rocker getting loose resulting in off centre.
As per drg.this dia is 100 micron less than Head punch Indent.
Slide 10
D M A I C
SEG NCU Study of 502
Green Roller Length = 25.817, Tolerance : +0.05/-0.153Finish Roller Length = 25.692, Tolerance : +0.102/-0.254
Recess Depth = 0.41 to 0.51After heading
Imported Hard Stock have recess depth of 510 – 550 microns.Rollers headed in-house have recess depth between 410 – 430 microns.
COMPARATIVE STUDY OF RECESS DEPTH
Slide 11
D M A I C
Kappa Study _ Visual
Eol
_SB
0.00
0.25
0.50
0.75
1.00
0 1
EOL_1
0
1
Mosaic Plot
EO
L_1
01
7 2 8 3
911
15 5 20
Eol_SBCount 0 1
Contingency Table
ModelErrorC. TotalN
Source 1 18 19 20
DF 0.033868 11.212835 11.246703
-LogLike0.0030
RSquare (U)
Likelihood RatioPearson
Test 0.068 0.067
ChiSquare 0.7947 0.7952
Prob>ChiSq
LeftRight2-Tail
Fisher's Exact Test 0.7786 0.6045 1.0000
Prob
0.047619Kappa
0.182141Std Err
Kappa measures the degree of agreement.
TestsOff line inspector Vs Roller Inspector
Slide 12
D M A I C
Kappa Study _ VisualE
OL_
1
0.00
0.25
0.50
0.75
1.00
0 1
MASTER
0
1
Mosaic Plot
MA
STE
R
0
1
9 3
0 8
12
8
9 11 20
EOL_1CountTotal %Col %Row %
0 1
Contingency Table
ModelErrorC. TotalN
Source 1 18 19 20
DF 7.014755 6.748022 13.762776
-LogLike0.5097
RSquare (U)
Likelihood RatioPearson
Test 14.030 10.909
ChiSquare 0.0002 0.0010
Prob>ChiSq
LeftRight2-Tail
Fisher's Exact Test 1.0000 0.0013 0.0014
Prob
0.705882Kappa
0.149631
Std Err
Kappa measures the degree of agreement.
TestsRoller Inspector Vs Master
Slide 13
D M A I C
Kappa Study _ VisualE
ol_S
B
0.00
0.25
0.50
0.75
1.00
0 1
MASTER
0
1
Mosaic Plot
MA
STE
R
01
10 25 3
128
15 5 20
Eol_SBCount 0 1
Contingency Table
ModelErrorC. TotalN
Source 1 18 19 20
DF 0.547462 10.699240 11.246703
-LogLike0.0487
RSquare (U)
Likelihood RatioPearson
Test 1.095 1.111
ChiSquare 0.2954 0.2918
Prob>ChiSq
LeftRight2-Tail
Fisher's Exact Test 0.9422 0.2962 0.3473
Prob
0.222222
Kappa
0.213691
Std Err
Kappa measures the degree of agreement.
TestsOffline Inspector Vs Master
Slide 14
D M A I C
Future Action PlanSl. No. Reason for SEG NCU Action Status
1. Heading Defect
Off center FOP indent dia to be reduced by 500 microns
New FOP ordered.
Punch Holder getting loose frequently
Same repaired Complete
Head Punch recess depth to be increased
Ordered for all part nos. Implemented.
2. Empty Disc Quarantine the lot Implemented
3. Size variation at Constant Stock Control size at Constant stock within +/- 10 mics.Use roller reject gate after constant stock
Implemented
4. Lack of knowledge on max passable limit Training to be provided to off line and roller inspectors on max passable limit
Conducted by Naresh. Kappa study to be done.
Slide 15
Control PlanOperation or Process
Step CharacteristicMeasurement or Review Method Responsible Frequency Type of Control Signal
Corrective Action Responsible
Heading operation Roller recess depth
Master Operator / PE Every 30 mins - 3 pcs
Check for correct head punch recess depth
Incoming inspection of head punches and approval to run
Replace the head punch
Tool Room
Heading operation Alignment of head punch and FOP.
Visual - Double recess
Operator / PE Every 30 mins - 3 pcs
Visual Double recess or non-uniform thickness of SEG face
Stop the machine and proper alignment to be done. If required, maintenance team to be involved
Operator / Maintenance
C/S grinding Size and Taper Master. Taper should be between 0 to -7 microns. Size should be between +5 to -10 microns.
Operator / PE Every 30 mins - 3 pcs
On line gauging and keeing the reject gate open
Correct the size and taper by dressing the regulating wheel or by adjusting the blade ht.
Operater / PE
SEG grinding Disc pressure As per the set up manual
Operator / PE At the time of set up
Manual Improper grinding of SEG
Increase of decrease pressure
Operator / PE
Max passableunderstanding
SEG Visual As per themax passablemanual
Naresh Behara Review to bedone everyquarter
Display of maxpassable limitson the shopfloor
Lack ofconcurrence within theoffline androller inspector
Training Naresh
Slide 16
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