Six Sigma Green Belt Project 1250-XX Covers Reduction of Raw Material Cost by Utilizing Regrind
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Transcript of Six Sigma Green Belt Project 1250-XX Covers Reduction of Raw Material Cost by Utilizing Regrind
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Six Sigma Green Belt Project
1250-XX CoversReduction of Raw Material Cost by Utilizing
Regrind
Green Belt Candidate, Tempe 07/13/07
-Define-
The purpose of this project is to determine if the blending of 25%
regrind into the GE Ultem 1000 will significantly change the Key
dimensional and visual characteristics of the 1250-XX covers. We
will focus on the 1250-05 for data collection as this is our
highest volume part for this Customer in this category.
If successful, this will eliminate the scrapping of the GE Ultem
1000 runners plus reduce the amount of virgin material necessary to
complete the orders.
-Process Map- Material Purchasing
-Measure-MSA Instructions
Instructions:-Using the Zeiss CMM program 1250-05 Six Sigma Post
Only, run sample parts in order. Samples are identified 1-10.Setup
(See pictures below):Place 1.500 spacer in H2.(2x .750)Place .750
spacer in H7. Position 1250-05 sample upside down on spacer with
gate at 45 degree angle to the bottom left. Snug down with second
.750 spacer. Follow instructions contained in program for Base
Alignment criteria.
Gate at 45 Degrees
-Measure- Measurement System Analysis
Measurement System Analysis contd.
Less than 10% of the tolerance is taken up by measurement error
indicating that the Zeiss CMM program is an acceptable way to
accurately measure the Key characteristics.
Gage R&R %ContributionSource VarComp (of VarComp) Total Gage R&R 0.0000000 0.99 Repeatability 0.0000000 0.99 Reproducibility 0.0000000 0.00 Part-To-Part 0.0000002 99.01 Total Variation 0.0000002 100.00
StdDev Study Var %Study Var %ToleranceSource (SD) (5.15*SD) (%SV) (SV/Toler) Total Gage R&R 0.0000483 0.0002488 9.95 2.49 Repeatability 0.0000483 0.0002488 9.95 2.49 Reproducibility 0.0000000 0.0000000 0.00 0.00 Part-To-Part 0.0004832 0.0024885 99.50 24.88 Total Variation 0.0004856 0.0025009 100.00 25.01
Number of Distinct Categories = 14
-Measure-Key Dimension Capability using 100% Virgin
Material
-Measure-Key Dimension Capability using 100% Virgin
Material
-Measure-Key Dimension Capability using 100% Virgin
Material
-Measure-Key Dimension Capability using 25% Regrind
-Measure-Key Dimension Capability using 25% Regrind
-Measure-Key Dimension Capability using 25% Regrind
-Measure-Key Dimension Capability using 100% Regrind
-Measure-Key Dimension Capability using 100% Regrind
-Measure-Key Dimension Capability using 100% Regrind
-Analyze-
A t-Test is being used to show that there is no significant
difference in the means between the 100% Virgin material and the
Virgin material with 25% Regrind. With the P-value being greater
than Alpha (.05), we fail to reject the Null Hypothesis (Ho) on all
3 Key Characteristics.
-Analyze-Contd.
-Analyze-Contd.
Samples were run with 100% Regrind to see what effect it had on the
Key Characteristics. t-Tests were used to show if a significant
difference in the means had been caused by the change. With
P-values remaining greater than Alpha (.05), we fail to reject the
Null Hypothesis (Ho) on all 3 characteristics proving there is no
significant difference in dimensional readings when 100% Regrind is
used.
-Analyze-Contd.
-Improve-
The Improvement phase will implement the usage of 25% Regrind added
to the virgin material during normal production runs. The Work
Order template will be updated in the Shared Directory to
accurately reflect the percentage of regrind allowed. Correct usage
of material will be verified during the QA Sign-In and initialed.
The Bill of Materials will also be amended.
-Control-
The Customer defined Key Characteristics will be monitored after
the introduction of regrind during the molding operation using a
variety of tools. Sign-In and In-Process dimensional inspection
criteria are controlled and communicated via the Mold Data Book.
The QA Sign-In at the start of the run will include the Customers
current A-079 inspection form available from their Customer
Website. In-Process data will be entered into real-time SPC Charts
in the Quality Control Lab and will be monitored by Quality
Inspectors. Any unusual variation in the SPC Charts will be
investigated. Out of specification product will be quarantined and
properly labeled with an Non Conforming Material Report per the ISO
standard and dispositioned accordingly.
-Control-
Copy of Mold Data Book Page- In-process Dimensional Inspection
criteria.
Copy of Mold Data Book Page- Sign-In Criteria
-Control-
Sample Customer A-079 Inspection Form
-Control-
Sample SPC Chart
Copy of Blank NCMR
-Cost Savings-
-Cost Savings-
Extrapolated to include all the 1250-XX Covers that do not specify
100% Virgin Only including -02, -05, -08, -10, -11, -12:
-Conclusion-
After measuring samples run with 25% Regrind/75% Virgin and samples
run with 100% Regrind, it has been concluded that there were no
significant differences or changes in the Customers Key Dimensions.
Cpk levels ranged between 2.64 and 9.94 indicating all values are
well above the 2.00 Cpk of a stable 6-sigma process. Taking into
account normal process variation and the likeliness that the
process may drift, it can be assumed that the values will remain
within the Customers specifications. Tensile strength testing will
need to be done by the Customer to verify overall strength and
integrity has not been compromised due to this change.With an
annual savings of $5,687.34 for the -05 configuration, the
potential cost savings if applied to all of the 1250-XX part
numbers would be $13,655.25 annually.