(Advanced Innovation Group) Reducing Leakage Rate - Define Phase

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DMAIC

Project Name : Seam Welding Leak & PuncherProject Owner : S.N. Dwivedi

Smarter Solution through Six Sigma

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Project Progress Overview

D1. Map Project

D2. Approve Project

M1. CTQ Characteristics& Standards

M2. Measurement System Analysis

M3. Data Collection

A1. Baseline Process

A2. Performance Objective

A3. Identify Drivers of Variation

I1. Screen for Vital Xs

I2. Screen for vital Xs

I3. Define Improved Process

C1. MSA on Xs

C2. Improved Process Capability

C3. Establish Control Plan

Key Deliverables: • List of Customer(s) and

Project CTQs• Team Charter• High Level Process Map

(COPIS)• CAP Plan (Optional)• Preliminary CBA, if

applicable

• QFD / CTQ Tree• Operational definition,

Specification limits, target, defect definition for Project Y(s)

• Data Collection Plan• Measurement System

Analysis

• Baseline of Current

Process Performance• Normality Test • Statistical Goal

Statement for Project• List of Statistically

Significant Xs

• List of Vital Few Xs• Transfer Function(s)• Optimal Settings for

Xs• Confirmation

Runs/Results• Tolerances on Vital

Few Xs

• MSA Results on Xs• Post Improvement

Capability• Statistical Confirmation

of Improvements • Process Control Plan• Process Owner Signoff• Final CBA, if applicable

Tollgates:Planned

Completed

10/June/2010 11/March/2010 mm/dd/yyyy mm/dd/yyyy mm/dd/yyyy

XXXXXX 15/March/2010 mm/dd/yyyy mm/dd/yyyy mm/dd/yyyy

Steps:

Tools: Survey Focus Groups Interviews ARMI, Stakeholder

Analysis In/Out of Frame Threat vs. Opportunity

Matrix Other ______________

Data Collection Plan Continuous Gage R&R Attribute Gage R&R Sample Size Calculator Other ______________

Basic Statistics Histogram Dot Plots Box and Whisker Plots Run Charts Normality Testing Continuous/Discrete Zst, Zlt Benchmarking Detailed Process Mapping Moments of Truth Nature of Work Flow of Work Fishbone Hypothesis Testing Regression Analysis Other ______________

DOE Pugh Matrix New Process Mapping FMEA on new process Process Modeling /

Simulation Other ______________

Continuous Gauge R&R Discrete Gauge R&R Control Charts Hypothesis Testing CAP Plan Control Plan Other ______________

Define Measure Measure Analyze Analyze Improve Improve Control Control

Overview

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Define

1. Map the Project2. Project Charter3. Terms and Acronyms Used4. ARMI & Communication Plan5. COPIS6. Process Map

04/14/234

Customer Sample CommentsKey Output Characteristics

Important to Customer (CTQ's)

Mr.

Kumar(Factory

Manager)

Very High in house seam

Welding Leak at Bubble Tank &

customer also not satisfy with

this operation.

Clint satisfaction

through increase

sealing leak PPM

Mr. Jay Prakash

(HOD & DGM

Operation)

Rework & Rejection Cost

increasing due to sealing leak &

puncher trend increasing.

Rejection & Rework

Cost increasing as well

as PPM also.

Bubble Tank (leak

testing) & end

line Users

Welding not as good as

customer demand .

Leak PPM so high

DefineMap the Project

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DMAIC

DIVISON: Tecumseh, Ballabgarh DEPT: Paint Shop & Final Assly DATE: 2.07.2013

PROJECT TITLE:

ELIMINATE SEAM WELDING PUNCHER & REDUCE SEAM WELDING LEAKS (Internal & Customer end)

A) BACKGROUND & REASONS FOR SELECTING THE PROJECT:

Repeated customer complaint of leakage from Seam welding at customer end 30 ppm.

Very High in house Leak rate at Bubble Tank : 11350ppm & puncher - 348ppm

Repairing & Rejection cost so high (Rs.0.27/Compressor)

B) AIM OF THE PROJECT:

Bring down the Leak rate on MIG welding of compressor to 8000ppm & Puncher - 200 ppm

Customer Rejection due to MIG welding failure to Zero ppm

C) CHAMPION'S NAME: D) TEAM LEADER

Jay Prakash S N Dwivedi

E) TEAM MEMBERS:

Manoj Jayant Ramesh Kumar

Saty Narayan Vikram Ramesh Sharma

F) CHARACTERISTICS OF OUTPUT OF PRODUCT/PROCESS & ITS MEASURES

Welding Quality

housing gap not fill complete

4. EXPECTED COST SAVING (IN RS.) -- Rs. 6.2 Lakh

5. MEETING FREQUENCY: WITH CHAMPION WITHOUT CHAMPION

Weekly Alternate Day

INITIALS:

CHARACTERISTICS MEASURES DEFECT DEFINITION

Jay Prakash

Air bubble from Compressor in Leak testing tank

Incomplete welding

Welding uniformity

Leakage

Weld Spatter

S. Saxena

PROJECT LEADER CHAMPION FACTORY MANAGER

S.N. Dwivedi

Project Charter

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In Scope:

Ok compressor from white room , pickup comp. from welding conveyor & load on fixture of welding m/c ,welding gas input , torch position, welding quality, leak test at bubble tank,

Out of Scope:

Leaky compressor supply to customer end.

Welding leak compressor generate at welding m/c.

Business Case: ABC Co.

Paint shop & Final assly.

Problem Statement:

Goal Statement:

Project Charter

Target Date Actual Date

Start Date 02.07.2013 Xxxx

Define 05.07.2013

Measure 12.7.2013

Analyze 25.7.2013

Design 12.8.2013

Verify 20.8.2013

High Level Project Plan

Define

ELIMINATE SEAM WELDING PUNCHER & REDUCE SEAM WELDING LEAKS (Internal & Customer end)

After white room during upper & lower housing welding there will be generate leaks deduct at bubble tank charging 220psi pressure inside the compressor.

Its has been observed in last 2-3 months, Repeated customer complaint of leakage from Seam welding at customer end is 30 ppm.

In Business prospective this is Very High in house Leak rate at Bubble Tank : 11350ppm & puncher - 348ppm.

Bring down the Leak rate on MIG welding of compressor to 8000ppm & Puncher - 200 ppm

Customer Rejection due to MIG welding failure to Zero ppm

Project Owner : Mr. S.N . Dwivedi

Champion : MR. Sanjeev Saxena

Sponsor : Mr. Jai Prakash

MBB : Mr. Paranay

BB : Mr. Vikas

GB : Mr. S.N. Dwivedi

Team Member : Ramesh kumar, Manoj Kumar, Satya narayan, Ramesh sharma, Jayant pahuja,

04/14/237

DefineSealing Leak

2000

4000

6000

8000

10000

12000

14000

Comp/Day 11153 12467 9651 10558 10609 13344

Target 10000 10000 10000 9000 9000 9000 8000 8000 8000 7500 7500 7500

Jan' 13 Feb' 13 Mar' 13 Apr' 13 May' 13 Jun' 13 Jul' 13 Aug' 13Sept'

13Oct' 13 Nov' 13

Dec' 13

9551

1129

7

2500

5000

7500

10000

12500

YTD- 12 YTD- 13

04/14/238

Define

348

9676

47 41

0

50

100150

200

250

300

350

400450

500PP

M

SealingPuncher

Tubedamage

Paint inside Waterinside

Housingdamage

Problems

Selection criteria of the Problem

04/14/239

Definitions:

Indicators Definition

PPMPARTS PER MILLION

FM FACTORY MANAGER

Sr. SENIOR

DGM DEPTY GENERAL MANAGER

Terms and Acronyms Used Define

04/14/2310

Key Stakeholders Define Measure Analyze Improve Control

FACTORY MANAGER

A R I I I

DGM PRODUCTION A, I R A, I M I

SR. MANAGER- QUALITY

A,I A,I A,I M A

MBB R, I R, I R, I

BB M M M

GB M M M

MEMBER (5 M M M

Message Audience Media Who When

PROJECT STATUSSR. MANAGER- QUALITY & DGM

PRODUCTION, MBB, BB,EMAIL S.N. Dwivedi WEEKLY

TOLL GATE REVIEWSR. MANAGER- QUALITY & DGM

PRODUCTION, MBB, BBEMAIL S.N. Dwivedi FORTNIGHTLY

Team Members Meeting

Team Members Morning Meeting S.N. Dwivedi DAILY

When Populating the Stakeholder, consider the ARMI:• A= Approver of team decisions• R= Resource or subject matter expert (ad hoc)• M= Member of team• I= Interested Party who will need to be kept informed

Communication PlanCommunication Plan

DefineARMI WorksheetARMI Worksheet ARMI & Communication Plan

04/14/2311

Customer Output Process

Input Supplier

1. WHO are your primary customers?(From Step A)

2. WHAT does the customer receive? (Think of their CTQ’s)

3. What STEPS are Included in the Process today? (high level)

4. What is provided to START the process?

5. Who PROVIDES the input?

(Who) (Nouns) (Verbs) (Nouns) (Who)

COPIS Define

ESGWeld ShopWhite Room

Process parameter

Lower & Upper housing with internal parts

Mig Wire

Welding Gases

Machine

Operator

Check process parameterLoad compressor on machine

Shut the door

Run machine

Pull up the door

take out the compressor

Welded compressor

Bubble tankLeak testingFinal testingusers

04/14/2312

Process Map Define

Seam welding

Plug removal

Coupler insertion

HP charge into compressor

Bubble testing

Insert earth & terminal plug

Pre treatment

Release HI pressure fittings

Painting

6.60/1

6.25/7 3.30/1 5/2 6.60/2

5.34/1

3.90/16.60/0

Total Man Power = 27

6.58/2

Seam Welding to Dehydration

Insert suction, process, discharge

tube5.81/2

Load on paint

conveyor

5.41/2

Insert internal plug into process tube

Remove external plugs

4.55/26.17/1

Attach dehydrationhoses

6.18/1

Remove hoses

Attach plug & Charge Nitrogen

5.57/16.61/1

Throughput Time : 90.47 sec

Process Flow Chart

04/14/2313

Measure

1. Data Collection Plan2. Measurement System Analysis3. Process Capability

04/14/2314

Y OperationalDefinition

DefectDefinition

PerformanceStandard

Specification Limit

Opportunity

Mode of collecting Data

Y Data Type UnitDecimal to

be Used

Data Base Container

Existing or new data

base

If New when data base would be

ready.

Plan start date for

DCP

Data Collection Plan

Equipment Used for

measurement

Equipment Calibration Information

ResponsibilityAny

Training need

Operator Information

Measure

04/14/2315

Measurement System Analysis

Rule Rule Description Acceptable Result

AR&R % of Tolerance

<10%

B% Contribution (R&R Std deviation)

Smaller than Part-to-part

variance

CNumber of distinct categories

>4

Overall Gage result

Minitab Descriptive Stats

Insert Minitab session window descriptive stats.

For discrete data use the attribute gage study exhibit from Minitab

Measure

04/14/2316

Process Capability Measure

04/14/2317

1. DCP for Potential Xs2. Identify Potential Xs3. DCP for Potential Xs4. Basic Analysis for Project Y5. Checking for Impact of ...... on Y6. Hypothesis Summary7. MSA results of Impacting Factors

Analyse

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Identify Potential Xs Analyse

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DCP for Potential Xs

Potential Cause Type of Data Collection Method

Test to be Used Visualization plot Used

Outlining the Data Collection Steps for Xs

Analyse

04/14/2320

Basic Analysis of Project Y

Randomness Study Randomness Study Normality StudyNormality Study

Randomness & Shape Study

Analyse

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Basic Analysis of Project YStudy Spread and Central Tendency

Spread Study Spread Study Central Tendency StudyCentral Tendency Study

Analyse

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Statistical Interpretation of relationship

Graphical DepictionGraphical Depiction Hypothesis ResultHypothesis Result

Inference :Inference :

Checking for Impact of ……on Y Analyse

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Checking for Impact of ……on Y


Analyse

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Hypothesis Summary

Sl. No.

Factor P Value Graphical Tool Used

Inference Next Steps

Summary of Impacting Factors

Analyse

04/14/2328

MSA Results of Impacting FactorsChecking the Validity of the data of the impacting factors

Sl. No.

FactorMSA

Method Used

ResultRCA for Problems

Next Steps

Analyse

04/14/2329

Improve

1. Screening of the Impacting Factors2. Action Plan for Improving the Factors3. Basic Analysis of Improved Y4. Pre–Post Analysis of Project Y5. Pre-Post Analysis of Factor6. Improve Summary – Take Aways

04/14/2330

Screening of the Impacting FactorsPrioritize the Impacting Factors

Improve

04/14/2331

Action Plan for Improving the Factors

# Pain Area Root Cause Improvement IdeaImplementatio

n Owner

Implementation Status

Improve

04/14/2332

Basic Analysis of Improved Y


Randomness, Shape , Spread & Centering Study


Improve

04/14/2333

Pre-Post Analysis of Project YStatistical Validation of Impact



Improve

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Pre-Post Analysis of Project YStatistical Validation of Impact



Improve

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Pre-Post Analysis of FactorStatistical Validation of Impact



Improve

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Improve

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Improve

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Improve

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Improve Summary – Take Aways Improve

04/14/2340

1. Control Plan & FMEA on Control Plan2. Time Series Study of Y – Pre & Post3. Control Charts & Inference for Y – Pre & Post4. Basic Analysis of Improved Y5. Establish Process Capability6. Control Charts & Inference (for X1)7. Control Charts & Inference (for X2)8. Cost Benefit Analysis and Sign Off

Control

04/14/2341

Control Plan & FMEA on Control Plan

What’s Controlled Goal/Spec Limits Control MethodWho/What Measures

Where Recorded

Decision Rule /

Corrective Action

SOP

Control

04/14/2342

Time Series Study of Y – Pre & Post Control

04/14/2343

Control Charts & Inference For Y – Pre & Post Control

04/14/2344

Basic Analysis of Improved Y


Randomness, Shape , Spread & Centering Study


Control

04/14/2345

Z Bench (Long Term Sigma)

Short Term Sigma(Long Term Sigma +1.5)

Process Capability – Post Implementation

Establish Process Capability Control

04/14/2346

Control Charts & Inference (For X1) Control

04/14/2347

Control Charts & Inference (For X2) Control

04/14/2348

Cost Benefit Analysis & Sign Off

Benefit Source Unit Benefit Units Impacted Total Benefit

Cost Reduction

Enhanced Revenues

Labour Reduction

Decreased Overhead

COPQ Cost Reduction

Control

04/14/2349

04/14/2350

What to see more of Want to see less of

Stakeholder Analysis

04/14/2351

Indicators Definition

Terms & Definitions Used

04/14/2352

RASIC

Education

(Advanced Innovation Group) Reducing Leakage Rate - Define Phase