Build Up Reduction on extrusion process
- 1. ConMed Chihuahua Six Sigma Green Belt Training – 2st.Wave Chihuahua, Mexico January 2013
- 2. Project Team Members … • Oscar Macias GB leader • Jose Luis Sanchez • Alfredo Roacho • Gildardo Parra - Champion • Eduardo Rodriguez • Cristina Castillo • Manuel Saucedo • Jorge Marquez • Ruben Vizcarra Black Belt Scrap Reduction by contamination in tube. at Extruder # 1 & 2 September 2012 - January, 2013 Define
- 4. Attributes agreement analysis Resina cruda Interna 1 Punto negro 2 Resina quemada 3 Resina cruda externa 4 Pieza bien 5 21 100.0 97.5 95.0 92.5 90.0 87.5 85.0 Appraiser Percent 95.0% C I Percent 21 100.0 97.5 95.0 92.5 90.0 87.5 85.0 Appraiser Percent 95.0% C I Percent Date of study: Reported by: Name of product: Misc: Assessment Agreement Within Appraisers Appraiser vs Standard Measure
- 5. Gage R&R Study - ANOVA Method Only with bag Part-to-PartReprodRepeatGage R&R 100 50 0 Percent % Contribution % Study Var 2 0 1 9 1 8 1 7 1 6 1 5 1 4 1 3 1 2 1 1 1 0987654321 2 0 1 9 1 8 1 7 1 6 1 5 1 4 1 3 1 2 1 1 1 0987654321 1.0 0.5 0.0 Parts SampleRange _ R=0.45 UCL=1.158 LCL=0 1 2 20191817161514131211109876543212 019181 716151 413121 110987654321 24 16 8 Parts SampleMean __ X=12.1UCL=12.56LCL=11.64 1 2 2019181716151413121110987654321 24 16 8 Parts 21 24 16 8 Operators 20191817161514131 21110987654321 24 16 8 Parts Average 1 2 Operators Gage name: Date of study : Reported by : Tolerance: Misc: Components of Variation R Chart by Operators Xbar Chart by Operators Appraisers by Parts Appraisers by Operators Parts * Operators Interaction Gage R&R (ANOVA) only with bag 18 12 6 18 12 6 18 12 6 1 Operators C6 2 3 4 5 6 7 Mean 8 Mean 9 10 11 12 13 14 15 16 17 18 19 20 Mean 1 2 O perators Gage name: Date of study : Reported by : Tolerance: Misc: Panel variable: Parts Gage Run Chart of C6 by Parts, Operators Measure
- 6. Gage R&R Study - ANOVA Method With car Part-to-PartReprodRepeatGage R&R 100 50 0 Percent % Contribution % Study Var 20191817161514131211109876543212 019181 716151413121110987654321 2 1 0 Parts SampleRange _ R=0.575 UCL=1.480 LCL=0 1 2 20191817161514131211109876543212 019181 716151 413121110987654321 24 16 8 Parts SampleMean __ X=12.25UCL=12.84LCL=11.66 1 2 2019181716151413121110987654321 24 16 8 Parts 21 24 16 8 Operators 2019181716151413121 110987654321 24 16 8 Parts Average 1 2 Operators Gage name: Date of study : Reported by : Tolerance: Misc: Components of Variation R Chart by Operators Xbar Chart by Operators C6 by Parts C6 by Operators Parts * Operators Interaction Gage R&R (ANOVA) with car 40 32 24 40 32 24 40 32 24 1 Operators concarrito 2 3 4 5 6 7 Mean 8 Mean 9 10 11 12 13 14 15 16 17 18 19 20 Mean 1 2 O perators Gage name: Date of study : Reported by : Tolerance: Misc: Panel variable: Parts Gage Run Chart of con carrito by Parts, Operators Measure
- 7. Analyze
- 8. Affinity Diagram extrusoras en de build up Generacion Medio ambiente Medicion Metodo Material Maquinaria Mano de obra Turnos Falta de entrenamiento Arreglo de temperaturas inadecuadas Presion inadecuada Melt inadecuado Herramientas de limpieza no disponibles Plato rompedor dañado Pin, dado y cabezal dañado Tornillo dañado herramientas no adecuado Material para limpieza de particulas negras Material contaminado por Diferentes tamañosn de Pellets no uniforme Pellets deformados/ Formacion Limpieza de plato rompedor Acumulamiento de material Limpieza de dado, pin y cavezal Rango de temperaturas Limpieza de extrusora Gaylord descubierto Descomprimir resina con remo Gage para medir cucaracha cajas Generacion de particulas de las Diferentes tecnic as deoperadores por turno herramientas Controlnoadecuadodeinv entariode Faltade controleninventarios Faltadematerial Pellets tamaños de Diferentes inadecuada Tapa disponible Material delimpieza no Aus entis mo adecuado Balanc eo no Cause-and-Effect Diagram Analyze
- 9. 6’M why? hypothesis Cause demonstration of hypothesis Material Pellets improperly formed/ pellets with different size Inadequate cleaning materials Absence of inventory control / lack of material contaminated by black particles Material burned in the development of pellets Analyze
- 10. t W Analyze
- 15. Analyze
- 16. Analyze
- 19. • During the preview measurement not founded black particles in 250 gaylords Analyze
- 20. 6’M why? hypothesis Cause Demonstration of hypothesis Personnel Poor training Different knowledge between operators Shifts Different technique of operators by shift Analyze
- 26. 6’M Why? Hypothesis Cause Demonstration of hypothesis Method Cleaning of Screen plate Material accumulation Absenteeism/ unbalanced Temperature range Uncover Gaylord Unsuitable top Assembly of die in head Having a bad assembly of die will cause leaks resulting resin burned in the die Analyze
- 27. Analyze
- 31. Analyze
- 32. Analyze
- 33. Analyze
- 34. Analyze
- 35. Recommended parameters apply to an of extruder 7-barrels 0 50 100 150 200 250 300 350 Barrel # 1 Barrel # 2 Barrel # 3 Barrel # 4 Barrel # 5 Barrel # 6 Barrel # 7 Clamp Dado # 1 Dado # 2 TemperatureF ←Extruder 1 Extruder 2→ Analyze
- 38. Analyze
- 39. Analyze
- 40. Analyze
- 41. 6’M Why? Hypothesis Cause Demostration of hypothesis Measurement Not gage for build up measurement N/A Analyze
- 42. 6’M Why? Hypothesis Cause Demonstration of hypothesis Environment Generation of carton particles Uncontrolled environment Analyze
- 43. Analyze
- 44. 6’M Why? Hypothesis Cause Demonstration of hypothesis Machine Screen plate, Die, Head, Pin and Screw Damage The surface of all tooling through which flows the resin must be completely smooth without scratches or damage if there is damage in the tooling, the resin will accumulate in cracks or rough surfaces and burned in that area. Tools Cleaning not available If you do not have the right tools for cleaning machinery and equipment not cleaned properly You might still leave in the tooling, burned material Melt inappropriate Recommended melt for the PVC Flexible resin Pressure Inappropriate Analyze
- 51. Analyze
- 52. Analyze
- 53. Analyze
- 57. Analyze
- 60. Screen pack Arrey Ex. 1 ←Time Size→ Analyze
- 62. Screen pack Arrey Ex. 2 ←Time Size→ Analyze
- 64. IMPROVE
- 65. • Material Improvements. Improve Cause Improve Pellets improperly formed/ pellets with different size Inadequate cleaning materials 1. Apex Teknor provide the material until of Tennessee they fix the process in California, the date must be no longer than one month. 2. Is added to CIP 1003791 the size and shape of pellet uniform even with photographs. 1. We implemented a Kanban system for chemical inventory and is documented in the EWI- 068-M
- 66. Improve
- 67. Improve
- 68. Improve
- 69. Cause Improve Cleaning of Screen plate Temperature range Uncover Gaylord 1. We standardized the method of cleaning the plate breaking and documented in the EWI-068-M 2. The area was fitted with the necessary tools to properly clean your plate and inspect the work Method Improvements. 1. Validation of the extruder # 2 in temperature ramp- Improve Assembly of die in head
- 70. Improve
- 71. Improve
- 72. Improve
- 73. We standardized the method of assembly of die and the procedure is documented in EWI-068-M Improve
- 74. Improve Cause Improve Machine Improvements. Screen plate, Die, Head, Pin and Screw Damage Melt inappropriate Pressure Inappropriate 1. Validation of the extruder # 2 in temperature ramp- 1. We implemented the arrangement # 2 mesh to increase the pressures over 1000psi and is documented in the EWI-068-M set up of extruders. Identify each tooling, die and pin and will be creates a verification and replacement procedure.
- 75. This Procedure is documented in the EWI-068-M Improve
- 76. Improve
- 77. Improve
- 78. White Room Improvements. Implementar recorrido semanal 15 minutos con Supervisor e Ingenieros para revision de area y filtros Yosselyn Eslava / Oscar Macias / Luis Carrera / Jose Luis Sanchez / Miguel Baez Continuo a partir del 27- Sep-12 27 Sep: Se realiza primer recorrido. Ver anexo C. 4 Oct: Se realiza segundo recorrido. Ver anexo. Auditoria de areas de tecnicos de STB (equipo, gavetas) Carolina Carmona 27-Sep-12 27 Sep: Completado el 24 de sep. Ver anexo D. 4 Oct: Se lleva semanalmente. Se anexaran auditorias a reporte, se encuentran los tecnicos en espera de que llegue el carro SMED. Implementar en sistema TMS Mantenimientos programados para limpieza del exterior del equipo de extrusion Roel Ramirez Done 27 Sep Proponer junta con Nico / Rogelio / Roel para disposicion de equipo Oscar Macias / Yosselyn Eslava / Luis Carrera 27-Sep-12 27 Sep: Nico trae esa actividad. Gerardo esta investigando que se puede ir y que no, en espera de respuesta (Claudia) 12 oct Improve
- 79. • Validating Improvements. Improve JAN FEB MAR APRIL MAY JUNE JULY AUGUST SEP OCT NOV DEC EXTR UDE 0 UNCLASSIF 1 BAD MATERIAL 2 OPERATOR ERROR 3 ENGINEERING ERROR 4 QA SAMPLE 5 TEST MATERIAL 6 SCRAP DUE TO MACHINE SET UP $ 14,393.65 $ 14,432.12 $ 12,204.77 $ 8,529.78 $ 9,786.12 $ 5,973.11 $ 9,655.07 $ 11,896.28 $ 6,646.28 $ 4,848.35 $ 5,108.39 $ 3,045.88 7 OBSOLETE VIA ECN &/OR MARKTNG 8 MACHINE MALFUNCTION 9 RGA MATERIAL TOTAL EXTRUDE $ 14,393.6 5 $ 14,432.12 $ 12,204.77 $ 8,529.78 $ 9,786.12 $ 5,994.84 $ 9,655.07 $ 11,896.28 $ 8,003.65 $ 6,678.85 $ 5,108.39 $ 3,045.88 Cost Material $ 383,683. 53 $ 553,397.0 9 $ 428,925.3 9 $ 419,695.3 5 $ 529,390.6 9 $ 401,317.9 5 $ 400,704.9 6 $ 495,986.8 8 $ 370,875.9 7 $ 477,810.7 2 $ 363,633.2 1 $ 273,533.5 0 % Scrap 3.75% 2.61% 2.85% 2.03% 1.85% 1.49% 2.41% 2.40% 1.79% 1.01% 1.40% 1.11% 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 Semana#36 Semana#37 Semana#38 Semana#39 Semana#40 Semana#41 Semana#42 Semana#43 Semana#44 Semana#45 Semana#46 Semana#47 Semana#48 Semana#49 Semana#50 Semana#51 Libras Scrap por Semana de Extrusion Meta: 890 Lbs
- 80. Improve Economic Benefits of Project Baseline: Historical data (Scrap average first 9 months): $ 2,380.60 dlls per month. 0.53% of Scrap by contamination $ 28,567 dlls anual Achieved 0.079% of Scrap by contamination 85 % of improvement This improvement represents a potential saving of $24,282 dlls from the $28,567 historical data.
- 81. • PFMEA Update Improve –Mitigation of potential causes that generates scrap.
- 82. • Daily scrap monitoring. Control Daily meeting to review scrap
- 83. Control • Plan Control Update
- 84. Control • Follow up Activities Actividad Status Fecha de terminacion Responsible Actualizacion del CIP de la resina 1003791 En Proceso 28 de Enero del 2013 Cristina Castillo Implementacion de Kanban de Quimicos y Elaborar el procedimiento En Proceso 24 Enero Del 2013 Oscar Macias Validacion de Extrusora 2 Temperaturas Tipo Rampa 3 corridas de OQ y 3 Corridas de PQ En Proceso 14 De Febrero del 2013 Oscar Macias Implementar todas las tapas de los gaylors En Proceso 28 de Enero del 2013 Oscar Macias Documentar la mejora del ajuste de dado con torque establecido a 5lbf En Proceso 31 de Enero del 2013 Oscar Macias Mandar a Identificar los dados, pines y platos rompedores y elaborar procedimiento de reemplazo En Proceso 7 Febrero del 2013 Oscar Macias Documentar el arreglo de mallas para elevar la presion de extrusion a mas de 1000 Psi En Proceso 31 de Enero del 2013 Oscar Macias
- 85. Questions?