模具使用寿命延长

1OESixSigmaProjectToolingUseOptimizationStartDate: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:293072ControlImproveAnalyzeMeasureDefine•ProblemStatementThebudgetoftoolingincreasedtoomuchandfor2014thebudgetofitis4,140KRMB,In2015wewillget5%cutbaseonthenormalincrease,about200KRMB.•BusinessCaseReducingthecostoftoolingwhilstmaintainingqualityandsupplyofproduct.•GoalGoalMetricBaselineTargetEntitlementCostYearsaving(%)05%NA3CustomersToolingManagementOutputsProcessInputsSuppliersStartStopSIPOCControlImproveAnalyzeMeasureDefineMFGDirtyToolingHROperatorsDirtyToolingEHSDefectTabletsTS/EMDocumentationQATabletsReceiveUsedToolingCleaningPolishingandbuffingStoreCompressionMachineDecisionofSalesCallSetObjectiveCustomeragreeonmeeting?PlansalescallCollectinfofrom:File,collegues,EssBaseetcBusienssdealterminated.YESNONONewsalescall?YESYESNOTravelInvestigationsofneeds?DemonstrateFullfillneedsSolveproblemsCont.AIDINCBusinessdealclosed?NONextStepinAIDINCYESSetobjectiveforsalescall?NONeedmoreinfo?YESSetobjective?NOYESNOShow&tellDoescustomeradmitanyneeds?NOYESBookcallYES4ControlImproveAnalyzeMeasureDefineProcessMapofTooling–Moredetails?-OptionalSpecificationsNeedDriversCTQsCurrentGoalServiceLifeLifeTimeCal300BatchesCal350batchesCostreducetheannualcostoftoolingsaving%05%QualityAQLPassPass5WeneedtoreducethecostoftheTooling.(Sponsor)CTQKeyIssueVOCControlImproveAnalyzeMeasureDefineVOCYfortheprojectDefectDefinition:Lifetimeofpunchespernumberofbatches6ControlImproveAnalyzeMeasureDefineAnnualcostoftooling754=Costofnewsetofpunches(setof45)+costofreplacementofafewpunches(nodata)Annualcostoftoolingall6compressionmachines=Costofnewsetofpunches+costofreplacementofafewpunchesBysetof50or100punches6compressionmachine1yearbuyfor754x3setsof50Averagecostoftoolingperbatchoftablets(RMB)theThroughenhancethemaintenanceanddataanalysisestimatetheservicelifeoftheTooling7ControlImproveAnalyzeMeasureDefineCostoftooling-Usepuncheslonger??8•i-nexusID29307–Title:Toolinguseoptimization–Benefits:ReducethecostoftheToolingControlImproveAnalyzeMeasureDefinei-nexusSearch9ControlImproveAnalyzeMeasureDefineWhatquestionsdoyouwanttoanswer?123What’sthereasonofthebadtooling4Howlongistheservicelifeofabatchoftooling5DataOperationalDefinitionandProceduresWhatMeasureTypeDataTypeHowMeasuredRelatedConditionsSamplingNotes1BadnumbersOutputdiscreteBatchnumbersissueEveryBatch2ServiceLifeoutputdiscreteBatchnumbersnormalEveryBatch345WhatareyourplansforGageR&R?Howwillyouplotthedatayoucollect?DataCollectionPlan10ControlImproveAnalyzeMeasureDefineDataCollectionPlan11•Showmeansthroughwhichmeasurementswereverified–SOPPM-29ControlImproveAnalyzeMeasureDefineMeasurementSystemAnalysis12ForStock754theaverageservicelifeis300BatchesforCaland64BatchesforCen.ControlImproveAnalyzeMeasureDefineBaseline13ForFette3090theaverageservicelifeis355BatchesforCalD600and66BatchesforCenControlImproveAnalyzeMeasureDefineBaseline14ForKelianT400theaverageservicelifeis372BatchesforCalD600ControlImproveAnalyzeMeasureDefineBaseline15ForFette3200itheaverageservicelifeis58BatchesforCenControlImproveAnalyzeMeasureDefineBaseline16Thetooling(Cal)servicelifeon3090andT400arelongerthanon754ControlImproveAnalyzeMeasureDefine17Thetooling(Cen)servicelifeon3090islongerthanon754andFette3200iControlImproveAnalyzeMeasureDefine18ControlImproveAnalyzeMeasureDefineProcessCapability•Ppk754:0.73;T400:0.46;3090:0.49•AllstabilityandnormalityGoodperformance19ControlImproveAnalyzeMeasureDefineProcessCapability•Ppk754:0.84;3090:0.96;3200:0.65•Allstabilityandnormalityexcepton3200i20ControlImproveAnalyzeMeasureDefineCauseandEffectAnalysis20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21PeopleEnvironmentMethodMaterialsMachineMeasurementPotentialRootCausesControlImproveAnalyzeMeasureDefine220,150,140,130,120,110,10ContaminationinmgContaminationComparisonbySupplierItalyKoreaControlImproveAnalyzeMeasureDefineHypothesisTesting•ShowMinitabsessionfolder+graphsscreenshots–commentbottomofslides•CheckstabilityandnormalityTwo-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=9KoreaissignificantlyhigherthanItalien23ControlImproveAnalyzeMeasureDefineRegressionAnalysis•ShowMinitabsessionfolder+graphsscreenshots•Checkresidualsassumptions•Summarycommentatbottomofslide24ControlImproveAnalyzeMeasureDefineDOE•ShowMinitabsessionfolder+graphsscreenshots•Checkresidualsassumptions•Summarycommentatbottomofslide25IdentifiedRootCauses•ListidentifiedrootcausesControlImproveAnalyzeMeasureDefine26SelectedSolutionsControlImproveAnalyzeMeasureDefineHighlightSelectedSolutions27ControlImproveAnalyzeMeasureDefineRiskAssessment•Listdetails28C