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Body 294837 with seat valve damaged
Thought Process Map
Why Are Rejected The Valves?
Is The Raw Material good to assembly ?
Are The Material Involved inTest That Fail?
Test Machine works correctly? Is The AssemblyProcess Reliable
Are The Test Step Within Specification?
Are The Parts Assembled Correctly ?
Are The Parts Contaminated or Damaged?
Implement a Change or Improve in the Process
Implement Solution for Material Involved in Rejects
Verify DataReduce PPM’s?
goalGoal
MEASURE
ANALYZE
IMPROVE
CONTROL
Are The Parts Within Spec?
Relation Between the Failed Tests and the Material Specification Exists ?
Data Indicates That The Machine is Failing?
yes
no
yes
no
Some Test Step Exists That Fails Continuously
yes
no
no
yes yes
yesno
no
yesno
yes
Data Indicates That The Material is Reject Root Cause?
no no
yes
yes
no
no
yes
Implement Solution for Test Machine
no
yes
yes
no
yes
no
yes
no
yes
no
Test # 4 failed by bad body
Seat valve without spec finished 80Drawing 294837
DOE shows that 97.66% of rejects is caused by body seat valve damaged
Action Plan was implemented with supplier for parts certified
Improvement PPM’s of 256663 to 24066 or 90%
SIPOC
SUPPLIERS•- SQA Receipt Inspection (Mainframe QC10 instructions) •-Materials Dept.•-Machining Area•-Twist Inc •-Parker Hannifin•-Sun Strong Precision•-Asimco( 294837 body certified) •-H R Dept.•-Engineering Dept.•-H S & E Dept
PROCESS:SR-5 Valve Production
-Valves Assembly(assembled appropriate with good bodies)-Valves Tested-Valves Packaging
CUSTOMERS ( & requirements)
•-Production Planners•-Shipping Dept. (DON)•-Q.C. Dept. (Make parts by BW’s)•-On Time Delivery (DON)•-Mccoy Brothers•-Great Dane Trailers •-Deloupe Inc.•-Cottrell Inc•-Fountaine Trailer Co.•-Reitnover Inc.•-Trailmobile Canada Inc.
INPUTS OUTPUTS
•-Assembly Product on Time •-Spec BW-486-T Rev 4•-Assembly Complete•-Correct Packaging (Qty)•-Appropriate Identification ( Part Number)•-Correct Components•-Contamination Free•-Free Accidents Process
•-Materials within BW’s Specifications (Body 294837 .218 dia) •-Trained Operators•-Lubricated parts•-Control Documents•-Pressure Air•-Electricity•-Test Process (Program Adequate)•-Assembly Fixtures and Tools (Clutch Tools)•-Safety Norms
Process Map (Entradas /Salidas)
Sta.2Check Valves,
pipe plugs, adapter assembly
Sta.1Lubricate bodies
and cover assembly
Sta.3Piston open/close,
spring, cover assembly
Sta.4Test machine,
diaphragm assembly and packagingX’s Y’s
• C- Lubrication BW-650-M • CR-Materials (spec.)• C-Torque tool • C-Loctite BW-621-M• C- Air Pressure• CR-Impact tool•SOP-Instructions • C-Training Operators
•Subassy Body/Cover•Contamination free•Torque 120 in/p•Blow off parts•Parts Lubricated
• CR-Materials (spec.)• C-Torque tool• C-Loctite BW-621-M • C-Lubrication BW-650-M• CR-Impact tool•SOP-Instructions• C-Training Operators
• CR-Materials (spec.)• C-Torque 20 in/p • C-Fixture for assembly• C-Lubrication BW-650-M•SOP-Instructions• C-Training operators
KPOV
KPOV
KPOV
KPIV
KPIV
C= Controllable S= SOP N= NoiseCR= Critical
KPIV
KPIV
•Body with check valves•Torque 170,375 in/p•Parts lubricated•Loctite/aluminum chips Contamination
KPOV
•Valve assembly•Torque 20 in/p•Parts lubricated
•Valve tested•Leak <200 sccm•Parts lubricated•Parts rejected test #4
•SOP-Test specifications BW-486-T• CR-Pneumatic System• CR-Measurement instrument• C-Valves assembled• CR-Preventive Maintenance•SOP-Instructions• C-Training operators• C-Air Pressure
Variable Target Control
Material spec.(Body294837) .218 dia. , 80 microinch surface finished
nothing
Pipe plugs assembled contamination free Depends of operator
Test Machine Parker valves contamination free Depends of technician
: Baseline Statistics
Tested Pieces by Product2005
3858 387
6484993.86
5.58 0.56010000200003000040000500006000070000
SR-5 SR-2 SR-4
Product
Piec
es
0.00
20.00
40.00
60.00
80.00
100.00
%
tested pieces %
In the SR-5 Line, three different products are assembled (SR-5, SR-2, SR-4) , the 93.86% of these parts are of SR-5, for this reason we worked with this product
Product
Year 2005 tested pieces %
SR-5 64849 93.86
SR-2 3858 5.58
SR-4 387 0.56
Baseline Statistics
249488 PPM’s is the average of 2005 total PPM’s, it is the baseline to measure the project advance improvement
FTTSF Line SR-5 2005
0
50000
100000
150000
200000
250000
300000
350000
400000
Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec
PPM
's
PPM's 2005 Base Line 249488 ppm's Goal 20000 ppm's
SR-5PPM's 2005
Base Line
249488 ppm's
Goal 20000 ppm's
Jan 283738 249488 20000
Feb 352646 249488 20000
Mar 296490 249488 20000
Apr 258973 249488 20000
May 291596 249488 20000
Jun 265865 249488 20000
Jul 209520 249488 20000
Aug 267037 249488 20000
Sept 254695 249488 20000
Oct 144774 249488 20000
Nov 180881 249488 20000
Dec 187637 249488 20000
Graphical Methods
Tested Pieces by Product2005
3858 387
6484993.86
5.58 0.56010000200003000040000500006000070000
SR-5 SR-2 SR-4
Product
Piec
es
0.00
20.00
40.00
60.00
80.00
100.00
%
tested pieces %
Charts to determine the most important product and the base line•SR-5 is 93.86% of total production on the line•249488 ppm’s is the base line (2005 average)
FTTSF Line SR-5 2005
0
50000
100000
150000
200000
250000
300000
350000
400000
Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov DecPP
M's
PPM's 2005 Base Line 249488 ppm's Goal 20000 ppm's