模具使用壽命延長

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人機法環(huán)料模具材料批次差異使用前檢查方法不同人員技能水平差別大安裝操作不當造成損壞保養(yǎng)方法不合理設備老化嚴重設備異常造成模具損壞人為判斷的經(jīng)驗儲存環(huán)境物料異常人員意識工具不合適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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