Download - SEG NCU-Arnab marik

Reduce SEG NCU

ARNAB MARIK& Team

21st JAN 2015

Revision 11/29/01

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

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

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

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

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%

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.

D M A I C

SEG NCU Study of 502Off Centre at Header resulting in NCU after Grind

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.

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

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

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)


Test 14.030 10.909

ChiSquare 0.0002 0.0010

Prob>ChiSq

LeftRight2-Tail


Prob

0.705882Kappa

0.149631

Std Err


TestsRoller Inspector Vs Master

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)


Test 1.095 1.111

ChiSquare 0.2954 0.2918

Prob>ChiSq

LeftRight2-Tail


Prob

0.222222

Kappa

0.213691

Std Err


TestsOffline Inspector Vs Master

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.

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