模具使用寿命延长

1OESixSigmaProject

ToolingUseOptimization

StartDate : 01-09-2013Coach : XiangBillSponsor : WangFengProcessOwner : LiuYanqiProjectLeader : LiuYanqiTeamMembers : He,Meihua(MFG)

Li,Wenwei(TS)Gu,Tianhua(EM)

Ma,Jihao(QA)Zhang,Zhenyu,YuYongjia\MaoCindyEM=EngineeringandMaintenanceTS=TechnicalServicei-nexusID:293072ControlImproveAnalyzeMeasureDefineProblemStatement

Thebudgetoftoolingincreasedtoomuchandfor2014thebudgetofitis4,140KRMB,In2015wewillget5%cutbaseonthenormalincrease,about200KRMB.BusinessCase

Reducingthecostoftoolingwhilstmaintainingqualityandsupplyofproduct.GoalGoalMetricBaselineTargetEntitlementCostYearsaving(%)05%NA3CustomersToolingManagementOutputsProcessInputsSuppliersStartStopSIPOCControlImproveAnalyzeMeasureDefineMFGDirtyToolingHROperatorsDirtyToolingEHSDefectTabletsTS/EMDocumentationQATabletsReceiveUsedToolingCleaningPolishingandbuffingStoreCompressionMachine4ControlImproveAnalyzeMeasureDefineProcessMapofTooling–Moredetails?-OptionalSpecificationsNeed

DriversCTQsCurrentGoal

ServiceLifeLifeTimeCal

300BatchesCal

350batchesCost

reducetheannualcostoftoolingsaving%05%

QualityAQLPassPass

5WeneedtoreducethecostoftheTooling.(Sponsor)CTQKeyIssueVOCControlImproveAnalyzeMeasureDefineVOCYfortheprojectDefectDefinition: Lifetimeofpunchespernumberofbatches6ControlImproveAnalyzeMeasureDefineAnnualcostoftooling754=Costofnewsetofpunches(setof45)+costofreplacementofafewpunches(nodata)Annualcostoftoolingall6compressionmachines=Costofnewsetofpunches+costofreplacementofafewpunchesBysetof50or100punches6compressionmachine1yearbuyfor754x3setsof50Averagecostoftoolingperbatchoftablets(RMB)

theThroughenhancethemaintenanceanddataanalysisestimatetheservicelifeoftheTooling7ControlImproveAnalyzeMeasureDefineCostoftoolingUsepuncheslonger??8i-nexusID29307Title:

ToolinguseoptimizationBenefits:ReducethecostoftheToolingControlImproveAnalyzeMeasureDefinei-nexusSearch9ControlImproveAnalyzeMeasureDefineWhatquestionsdoyouwanttoanswer?123

What’sthereasonofthebadtooling4

Howlongistheservicelifeofabatchoftooling5

DataOperationalDefinitionandProcedures

WhatMeasureTypeDataTypeHowMeasuredRelatedConditionsSamplingNotes1

BadnumbersOutputdiscreteBatchnumbersissueEveryBatch2

ServiceLifeoutputdiscreteBatchnumbersnormalEveryBatch3

4

5

WhatareyourplansforGageR&R?Howwillyouplotthedatayoucollect?DataCollectionPlan10ControlImproveAnalyzeMeasureDefineDataCollectionPlan11ShowmeansthroughwhichmeasurementswereverifiedSOPPM-29ControlImproveAnalyzeMeasureDefineMeasurementSystemAnalysis12ForStock754theaverageservicelifeis300BatchesforCaland64BatchesforCen.ControlImproveAnalyzeMeasureDefineBaseline13ForFette3090theaverageservicelifeis355BatchesforCalD600and66BatchesforCenControlImproveAnalyzeMeasureDefineBaseline14ForKelianT400theaverageservicelifeis372BatchesforCalD600ControlImproveAnalyzeMeasureDefineBaseline15ForFette3200itheaverageservicelifeis58BatchesforCenControlImproveAnalyzeMeasureDefineBaseline16Thetooling(Cal)servicelifeon3090andT400arelongerthanon754ControlImproveAnalyzeMeasureDefine17Thetooling(Cen)servicelifeon3090islongerthanon754andFette3200iControlImproveAnalyzeMeasureDefine18ControlImproveAnalyzeMeasureDefineProcessCapabilityPpk754:0.73;T400:0.46;3090:0.49AllstabilityandnormalityGoodperformance19ControlImproveAnalyzeMeasureDefineProcessCapabilityPpk754:0.84;3090:0.96;3200:0.65Allstabilityandnormalityexcepton3200i20ControlImproveAnalyzeMeasureDefineCauseandEffectAnalysis20人机法环料模具材料批次差异使用前检查方法不同人员技能水平差别大安装操作不当造成损坏保养方法不合理设备老化严重设备异常造成模具损坏人为判断的经验储存环境物料异常人员意识工具不合适21People

Environment

Method

Materials

Machine

Measurement

PotentialRootCausesControlImproveAnalyzeMeasureDefine22ControlImproveAnalyzeMeasureDefineHypothesisTestingShowMinitabsessionfolder+graphsscreenshots–commentbottomofslidesCheckstabilityandnormalityTwo-sampleTforContaminationSupplierNMeanStDevSEMeanItalien60,112170,009390,0038Korea60,141830,007910,0032Difference=mu(Italien)-mu(Korea)Estimatefordifference:-0,0296795%CIfordifference:(-0,04101;-0,01833)T-Testofdifference=0(vsnot=):T-Value=-5,92P-Value=0,000DF=9KoreaissignificantlyhigherthanItalien

23ControlImproveAnalyzeMeasureDefineRegressionAnalysisShowMinitabsessionfolder+graphsscreenshotsCheckresidualsassumptionsSummarycommentatbottomofslide24ControlImproveAnalyzeMeasureDefineDOEShowMinitabsessionfolder+graphsscreenshotsCheckresidualsassumptionsSummarycommentatbottomofslide25IdentifiedRootCausesListidentifiedrootcausesControlImproveAnalyzeMeasureDefine26SelectedSolutionsControlImproveAnalyzeMeasureDefineHighlightSelectedSolutions27ControlImproveAnalyzeMeasureDefineRiskAssessmentListdetails28ControlImproveAnalyzeMeasureDefinePilotandImplementationPlanListdetails29StandardisationandDocumentationControlImproveAnalyzeMeasureDefineListdetailsofprocedures,templates,manufacturinginstructionsetc…,andwhenapprovedforuse,mmm/yyyyListdetailswhentrainingcompleted,mmm/yyyy30ResultsUsethetablebeloworuseabeforeandaftergraph.Summarycommentatbottomofslide.ControlImproveAnalyzeMeasureDefineGoalMetricBaselineTargetCurrentIncreaseABCYieldMonthlyABCYield(%)50.2(average)(JantoJun2011)≥60.0(average)65(average)(AugtoSept2011)01020304050607080Number

of

guarantee

claims

due

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