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High Volume Material Distribution System (Project ID: xxxxx )

March 14, 200x

Delphi Confidential2

D1: Charter TeamDate: September 28,200xProject Team Leader(s): Project Champion (s): Team Members: Project Sponsor:

Project Title:High Volume Material Distribution System (Project ID: xxxxx )

Project Details: When presses, requiring the high volume materials, need material they send a signal to the Central Distribution System which in turn sends the material through the feed system pipes to the press. As more presses came on line in plant XX we’ve noticed that presses, running high volume material, on several lines began shutting down due to lack of material. As more tools are in-sourced there is the potential that this condition will only worsen and be widespread throughout the plant.

Business Case addressed: Improve Machine Uptime.

Key Deliverables:

(Dates) Define: Sept/Oct. 200x Measure: October 200x Analyze: November 200x Improve: January 200x Control:February 200x

Critical Milestones: Determine root cause of downtime caused by the material distribution system.

Customers/ Suppliers who must be involved: Plant Manufacturing, Engineering, and PC&L “Must-Dos” in terms of Project scope: Identify causes of material flow problems.

Things definitely not in the project scope: Uptime issues other than material.

How the Project will be Measured: Machine Uptime.

Jim Altier

Champion(s) Deployment Champion Sponsor Master Blackbelt Green belts Finance(signatures to initiate project)

Champion(s) Deployment Champion Sponsor Master Blackbelt Green belts Finance

(signatures to close project)

Delphi Confidential3

D2: Scope ProjectProcess Name: Plant 47 High Volume Material Distribution System (Project ID Number 19907)Process Owner: Engineering

Suppliers Inputs Process Outputs Customers(Providers of the required resources)

(Resources required by the process)

(Top level description of the activity)

(Deliverables from the process) (Stakeholders who place the requirements on the outputs)

Manufacturing Engineering Material Spec. Manufacturing

Industrial Engineering Shot Size PC & LMatrerial is Fed to Presses

PC & L Distance

Manufacturing Frequency

Manufacturing EngineeringCentral Dist. System

Industrial Engineering Material Available Produce ProductPrioritize Signal

PC & L

Manufacturing

Manufacturing Engineering

Industrial EngineeringMaterial Available at Press Parts available for Shipping

PC & L

Manufacturing

6 5 1 2 3

Signal sent to Central

Distribution System

Press supplied with material

Parts

Produced

Delphi Confidential4

D2: Scope Project

“Y”Machine down due to lack of material

X1

Sequential loadvs..

Priority Load

Appears to be solved via priority

based software

X2

Blended materialover used. (DH9)

X3

Fur Balls

Regrind causesstrings

How do we fix this?

X4

Load & Purgesetting

Who has accessto the settings?

What do we meanby over used?

“Y”Machine down due to lack of material

X1

Sequential loadvs..

Priority Load

Appears to be solved via priority

based software

X2

Blended materialover used. (DH9)

X3

Fur Balls

Regrind causesstrings

How do we fix this?

X4

Load & Purgesetting

Who has accessto the settings?

What do we meanby over used?

Delphi Confidential5

D3: Identify Customers and Requirements

When presses, requiring the high volume materials, need material they send a signal to the Central Distribution System which in turn sends the material through the feed system pipes to the press. As more presses came on line in plant xx we’ve noticed that presses, running high volume material, on several lines began shutting down due to lack of material. As more tools are in-sourced there is the potential that this condition will only worsen and be widespread throughout the plant.

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M1: Identify Project Measure (Y)

Inputs Outputs Inputs Outputs Inputs Outputs

Inputs Outputs Inputs Outputs Inputs Outputs

Inputs Outputs Inputs Outputs

C Controllable Cr CriticalS SOP N Noise

Process Map (PMAP) Template

Tool/Part Req’d

Part designMaterial typeVolumeTool design

Cycle timeParts per hourMaterial usageMachine load

Associate tool to Press

Tool sizeMaterial typeMachine load

Press/Line assignment

Machine Production Schedule

Customer requirementsPC&L

Production run

Press Operating

ScheduleOperatorMaterial ToolNetwork

Finished parts

Material Request

Shot loader sensor Network signalto material system

Priority Call Program

Network requestPress numberMaterial usage rateMaterial on hand

Press loadsequence

Vacuum Load Cycle

Priority programMaterial valveMaterial dryer/hopper

Material conveyed

Shot loader Fill

Load timePurge timeMaterial specific gravityShot loader sensor

Request satisfied

SensorSatisfied ?

Yes

No

No Yes

Shut down

>3rd

Request ?

Inputs Outputs Inputs Outputs Inputs Outputs

Inputs Outputs Inputs Outputs Inputs Outputs

Inputs Outputs Inputs Outputs

Inputs Outputs Inputs Outputs Inputs Outputs

Inputs Outputs Inputs Outputs Inputs Outputs

Inputs Outputs Inputs Outputs

C Controllable Cr CriticalS SOP N Noise

Process Map (PMAP) Template

Tool/Part Req’d

Part designMaterial typeVolumeTool design

Cycle timeParts per hourMaterial usageMachine load

Associate tool to Press

Tool sizeMaterial typeMachine load

Press/Line assignment

Machine Production Schedule

Customer requirementsPC&L

Production run

Press Operating

ScheduleOperatorMaterial ToolNetwork

Finished parts

Material Request

Shot loader sensor Network signalto material system

Priority Call Program

Network requestPress numberMaterial usage rateMaterial on hand

Press loadsequence

Vacuum Load Cycle

Priority programMaterial valveMaterial dryer/hopper

Material conveyed

Shot loader Fill

Load timePurge timeMaterial specific gravityShot loader sensor

Request satisfied

SensorSatisfied ?

Yes

No

No Yes

Shut down

>3rd

Request ?

Delphi Confidential7

M1: Identify Project Measure (Y)

Characteristic – Availability

Operational Definition – Any time a machine is down because the material delivery cannot fill the demand.

Target – 0 downtime

Specifications –

Defect Definition – Any downtime

Name for the Measure – Machine down due to lack of material

Delphi Confidential8

M1: Identify Project Measure (Y)

MachinesMethodsMother Nature

Optimization Setting Change

PC&L Scheduling tool moves

Sensor Problems

ClogsMachine Load/Balance

Optimization of Settings

Measurements Materials Man

Machine down due to lack of material.

Variation of Material

Cause & Effect Definitions

Optimization Setting Change Ideal Setting for the load and purge.

PC&L Scheduling Tool Moves When PC&L schedules a tool on a line other than the assigned line.

Clogs Strings of material cause clogs in the system.

Sensor Problems Shot Loader sensor failure, won't send a signal for material.

Variation of material Filled material takes longer to move than unfilled.

Machine Load / Balance The lines where tools are assigned to run.

Optimization of setting Ideal Setting for the load and purge.

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M2: Data Collection Plan

Screen shot of a model develop by xxxxx xxxxx to better understand the workings of the system (vacuum) by modeling the variables.

Model developed in excel and copied into a access database currently being used.

Delphi Confidential10

M2: Data Collection Plan

Two different studies were conducted to determine the effects of material type and distance of the press from the central system on material flow rates. The first study measures the amount of material conveyed, based on the average of 3 loads of 4 seconds each, to the closest (xxx) and furthest (xxx) press form Region 1 on line 5. Seven different materials were conveyed to each press. The second study measured the amount of material conveyed to each of the 15 presses for a single 6 second load from Dxx (PAxxxxx – Blended Black).

Delphi Confidential11

M2: Data Collection PlanStudy 1:

The purpose of this study was to determine the effects of distance and material type on the flow rate per second of load time.Average load by material

0.0010.0020.0030.0040.0050.0060.0070.0080.00

DH9 DH11 DH13 DH16 DH2 DH4 DH6Hopper

oz o

f m

ate

ria

l

Press 502 (furthest)Press 515 (closest)

Mat'l Hopper

Press 502

(furthest)

Press 515

(closest) M3592001 PA66 HS IM DH9 59.73 75.20 M2279001 PA66 GF14 HS IM DH11 41.07 47.20 M3592008 PA66 HS IM DH13 29.60 20.27 M3592023 PA66 HS IM DH16 25.87 31.73 M3592012 PA66 HS IM DH2 18.93 13.07 M2279018 PA66 GF14 HS IM DH4 13.60 12.53 M3571008 PA6 GB20 GF10 HS DH6 11.47 20.00

Results:

Distance does not affect the amount of material conveyed for a given load time. Only the purge time needs to vary based on the distance the material is conveyed. Since the load time is the amount of time the material valve is open at the regional hopper allowing the flow of material into the vacuum stream it makes sense that the distance of the destination press would not have any affect on this process. The purge time would be affected because of the greater distance the material needs to be moved and the additional pipe that would need to be cleared as the distance is increased. The obvious outcome of the study is that the hopper takeoff probes are not properly adjusted for maximum flow. If the results of conveying from DH9, DH13, DH16 and DH2 to any single press are compared it is evident that DH9 has been optimized as it is the furthest away yet flowed more than twice the amount of material per second. The above group of hoppers all contain the same nylon 66 material.

The study does not show a correlation between material type or specific gravity of the material and flow rate, though this is known to have a significant effect. This is most likely being masked by the maladjustment of the takeoff probes.

LAYOUT DH9 DH1

DH10 DH2

51

4

51

2

51

0

50

9

50

8

50

6

50

4

50

2

DH11 DH3 DH12 DH4 DH13 DH5 DH14 DH6 DH15 DH7

51

5

51

3

511 X

50

7

50

5

50

3

50

1

DH16 DH8

VALVE VALVE

VALVE VALVE

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A2: Root Cause AnalysisStudy 2:

The purpose of this study was to verify the result in study 1 that distance does not affect load time, but only the purge time of the conveyance cycle.

Odd vs. Even Presses

503

505

507

509

511

513

515501

502504

506508

510512

514

70.00

80.00

90.00

100.00

110.00

120.00

130.00

oz o

f m

ate

ria

l c

on

ve

ye

d in

4

se

c.

Single 6 sec load (oz)

y = -0.0093x4 + 0.3441x3 - 3.7302x2 + 11.432x + 103.91

80.00

100.00

120.00

140.00

501 502 503 504 505 506 507 508 509 510 511 512 513 514 515

Press

oz o

f m

ate

ria

l

Results:

The results of conveying the same material from DH9 to each of the machines for 6 seconds on line 5 confirms that distance does not have a significant affect on amount of material conveyed per second of load time (blue line). The data points and trend lines (black line) are not as expected though. The data should trend slightly up from right to left in a linear fashion (red line). This would reflect the slight variation in conveyance between the closest and furthest press. The data indicates a problem, or sag, conveying to the presses in the middle of the bank. These are also the largest machines which would compound capacity issues as they require more material throughput. These machines were also retrofitted with larger shot loaders which may be the source of the variation, not due to the size, but possibly due to the design or fit causing leakage issues. Further investigation will be required.

Delphi Confidential13

A2: Root Cause Analysis

Hopper Press Load (oz)

DH9 501 119.20 DH9 502 100.80 DH9 503 117.60 DH9 504 108.00 DH9 505 106.40 DH9 506 96.80 DH9 507 114.40 DH9 508 92.00 DH9 509 87.20 DH9 510 92.00 DH9 511 100.00 DH9 512 95.20 DH9 513 125.60 DH9 514 124.00 DH9 515 120.00

Mat'l Hoppe

r Press 502 (furthest)

Press 515 (closest)

Ave oz per sec

M3592001 PA66 HS IM DH9 59.73 75.20 16.87 M2279001 PA66 GF14 HS IM DH11 41.07 47.20 11.03 M3592008 PA66 HS IM DH13 29.60 20.27 6.23 M3592023 PA66 HS IM DH16 25.87 31.73 7.20 M3592012 PA66 HS IM DH2 18.93 13.07 4.00 M2279018 PA66 GF14 HS IM DH4 13.60 12.53 3.27 M3571008 PA6 GB20 GF10 HS DH6 11.47 20.00 3.93

Ave oz per sec 7.15 7.86

The collective average ounces of material conveyed per second for all materials tested were 7.5. The range for the seven hoppers tested was between 3.9 and 16.9 ounces per second. These numbers were generated measuring 3 consecutive shots of each material for a four second load time. The large range in flow rate results indicates issues with the takeoff box ratio adjustments. Some of the variation could be contributed to differences in materials and fillers, but there are also large differences between same materials that only vary in color. Adjustments need to be made to the takeoff ratios during a shutdown period and further studies conducted to establish a new average flow rate to be used in the simulation calculations.

 Max possible

Lag as material is fluidized into the vacuum stream

The expected average, or theoretical flow rates, of unfilled material from an optimized hopper and takeoff box should be in the 15 to 20 ounces per second range. Glass filled material will be somewhat less due to the higher specific gravity and tendency to of the material pack.

Load Time Profile

0

5

10

15

20

25

30

1 2 3 4 5 6 7 8 9 10

Total Seconds of Load Time

Oz o

f M

ate

ria

l C

on

ve

ye

d

pe

r S

ec

on

d o

f L

oa

d T

ime

Max possible

Lag as material is fluidized into the vacuum stream

Delphi Confidential14

A2: Root Cause Analysis

Data indicates that we have 2 root causes that need action:

1. Load and purge settings: Need to be optimized.

2. Conveyance of material: Hoppers need work.

Roadblocks: Need machine downtime for Hoppers and need a plan for Load and Purge settings.

Delphi Confidential15

I1: Develop Solutions

The previous study indicated that material conveyance was the factor that needed addressed before other changes could have an impact.

During Independence week shutdown hoppers were re-worked to resolve conveyance issues.

The next slides will cover that data that was collected after the changes were made.

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I2: Test Solutions

Average load by material to press 515

0.00

20.00

40.00

60.00

80.00

100.00

120.00

DH9 DH11 DH13 DH16 DH2 DH4 DH6

Material Hopper

Ou

nc

es

pe

r lo

ad

Before

After

Delphi Confidential17

I2: Test Solutions

Delphi Confidential18

C1: Implement Solution Central Material System Take off Box Adjustment

The material take off box at the bottom of the regional material hoppers in the plant xx

have a pipe within a pipe configuration. The inner pipe has an oval hole which is the

material feed to the mold machines. This pipe can be adjusted by removing the 4 bolts on

the outside of the take off box at the bottom of the material hopper. Once the bolts are

off the pipe can be turned clockwise or counter clockwise until the bolt holes line up

again. So youu can position the hole in relation to how the material enters into the tube.

Typically the hole faces straight down when it comes from the factory. This is fine for

low density materials such as polypro but when you are trying to run glass filled nylon

you may have a problem. This is because the vacuum has to lift the material into the pipe

so it can be fed into the machine. The greater the density the harder it is to feed the

material into the pipe. By turning the inside pipe such that the hole is positioned slightly

upward allows the material to feed directly into the pipe. Now the vacuum pump does

not have to lift the material to get into the pipe and eventually to the mold machine.

Delphi Confidential19

C1: Implement SolutionThe outer pipe also has an opening and it spins over the inner pipe. The outer pipe has a

set screw that can be loosened and that will allow the pipe to spin around the inner pipe

which the material goes into. By turning this pipe you can adjust the material to air ratio

aspect of the material load to the press. Obviously when more of the inner pipe cut out is

covered the less material and more air will be allowed during a load. We have adjusted

the outer pipe so that the entire inner pipe cut out is exposed to maximize the amount of

material that is loaded. A picture is provided above to show the relationship of the inner

pipe and the outer pipe as install in the field. (Note: for clarity purposes only one of the

two pipe assemblies is shown. The other assembly is adjusted the same.

Reference Delphi assembly drawing number N7740-MIS-001 sheet # 1 and Novatec

detail drawing T81133C for the mechanical drawings used to assemble the vacuum

takeoff boxes.

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C2: Assess Capability

Material in ounces

7.5

(before)

22.67

(after)

Pump Capacity

used (before)

Pump Capacity used

(after)

Lines 1&2 124.9% 41.3%

Lines 5&6 147.6% 48.8%

Delphi Confidential21

C3: Close Project

Engineering estimated a $150,000.00 savings due to avoidance of addition vacuum equipment and installation.