Six Sigma Green Belt Project 1250-XX Covers Reduction of Raw Material Cost by Utilizing Regrind...

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

.010

K. Miller5-25-07

Zeiss

Misc:Tolerance:

Reported by:Date of study:

Gage name:

2.802

2.801

2.800

MikeKelleyBiljana

Xbar Chart by Oper.

Sa

mp

le M

ea

n

Mean=2.801UCL=2.801LCL=2.801

0.00015

0.00010

0.00005

0.00000

MikeKelleyBiljana

R Chart by Oper.

Sa

mp

le R

an

ge

R=4.67E-05

UCL=1.52E-04

LCL=0

MikeKelleyBiljana

2.8015

2.8010

2.8005

2.8000

Oper.

By Oper.

109876543211098765432110987654321MikeKelleyBiljana

2.8015

2.8010

2.8005

2.8000

Part IDOper.

By Part ID (Oper.)

%Contribution

%Study Var %Tolerance

Part-to-PartReprodRepeatGage R&R

100

50

0

Components of Variation

Pe

rce

nt

Gage R&R (Nested) for 2.798 +/- .0

Measurement System Analysis cont’d.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 %Tolerance

Source (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

151050

2.8017

2.8016

2.8015

2.8014

Xbar and R Chart

Subgr

Mea

n

Mean=2.802

UCL=2.802

LCL=2.801

0.00024

0.00016

0.00008

0.00000

Ran

ge

R=6.92E-05

UCL=2.26E-04

LCL=0

151050

Last 15 Subgroups2.80165

2.80155

2.80145

2.80135

Subgroup Number

Val

ues

2.8032.793

Capability PlotProcess Tolerance

III

III

IISpecif ications

Within

Overall

2.80162.80152.8014

Normal Prob Plot

2.80162.80152.8014

Capability Histogram

WithinStDev:Cp:Cpk:

0.000061427.17 8.01

OverallStDev:Pp:Ppk:

0.000064625.79 7.61

Process Capability Sixpack for 2.798(100%V)


Virgin Material

151050

0.1380

0.1378

0.1376

0.1374

Xbar and R Chart

Subgr

Mea

n

1

Mean=0.1377

UCL=0.1380

LCL=0.1373

0.0006

0.0004

0.0002

0.0000

Ran

ge

R=1.81E-04

UCL=5.92E-04

LCL=0

151050


0.1378

0.1376

0.1374

Subgroup Number

Val

ues

0.1400.136


III

III

IISpecif ications

Within

Overall

0.138000.137750.13750

Normal Prob Plot

0.13800.13760.1372


WithinStDev:Cp:Cpk:

0.00016064.153.44


0.00017863.733.10

Process Capability Sixpack for .140(100%V)


Virgin Material

151050

0.0074

0.0072

0.0070

0.0068

Xbar and R Chart

Subgr

Mea

n

Mean=0.007065

UCL=0.007337

LCL=0.006793

0.00045

0.00030

0.00015

0.00000

Ran

ge

R=1.45E-04

UCL=4.72E-04

LCL=0

151050


0.0071

0.0069

0.0067

Subgroup Number

Val

ues

0.010.00


III

III

IISpecif ications

Within

Overall

0.007300.007050.00680

Normal Prob Plot

0.00740.00700.0066


WithinStDev:Cp:Cpk:

0.000128113.01 7.63


0.000120213.87 8.14

Process Capability Sixpack for Parallel(100


Regrind

151050

2.8015

2.8014

2.8013

2.8012

Xbar and R Chart

Subgr

Mea

n

1

Mean=2.801

UCL=2.801

LCL=2.801

0.0003

0.0002

0.0001

0.0000

Ran

ge

R=8.01E-05

UCL=2.62E-04

LCL=0

151050

Last 15 Subgroups

2.8014

2.8013

2.8012

2.8011

Subgroup Number

Val

ues

2.8032.793


III

III

IISpecif ications

Within

Overall

2.80152.80132.8011

Normal Prob Plot

2.801502.801252.80100


WithinStDev:Cp:Cpk:

0.000071023.47 7.88


0.000089418.65 6.26

Process Capability Sixpack for 2.798(25%R)


Regrind

151050

0.13775

0.13750

0.13725

0.13700

Xbar and R Chart

Subgr

Mea

n

Mean=0.1374

UCL=0.1377

LCL=0.1370

0.0006

0.0004

0.0002

0.0000

Ran

ge

R=1.95E-04

UCL=6.37E-04

LCL=0

151050


0.1374

0.1372

0.1370

Subgroup Number

Val

ues

0.1400.136


III

III

IISpecif ications

Within

Overall

0.13780.13740.1370

Normal Prob Plot

0.137500.137250.13700


WithinStDev:Cp:Cpk:

0.00017283.862.64


0.00017583.792.60

Process Capability Sixpack for .140(25%R)


Regrind

151050

0.00735

0.00710

0.00685

0.00660

Xbar and R Chart

Subgr

Mea

n

Mean=0.006979

UCL=0.007317

LCL=0.006640

0.0006

0.0004

0.0002

0.0000

Ran

ge

1

R=1.80E-04

UCL=5.88E-04

LCL=0

151050


0.00730

0.00705

0.00680

Subgroup Number

Val

ues

0.010.00


III

III

IISpecif ications

Within

Overall

0.00760.00710.0066

Normal Prob Plot

0.00760.00710.0066


WithinStDev:Cp:Cpk:

0.000159710.44 6.31


0.000166210.03 6.06

Process Capability Sixpack for Parallel(25%


Regrind

151050

2.8018

2.8016

2.8014

2.8012

Xbar and R Chart

Subgr

Mea

n

1

Mean=2.801

UCL=2.802

LCL=2.801

0.0003

0.0002

0.0001

0.0000

Ran

ge

R=1.10E-04

UCL=3.59E-04

LCL=0

151050


2.8016

2.8014

2.8012

Subgroup Number

Val

ues

2.8032.793


III

III

IISpecif ications

Within

Overall

2.801702.801452.80120

Normal Prob Plot

2.801702.801452.80120


WithinStDev:Cp:Cpk:

0.000097517.10 5.19


0.000127113.12 3.98

Process Capability Sixpack for 2.798(100%R)


Regrind

151050

0.1378

0.1376

0.1374

0.1372

Xbar and R Chart

Subgr

Mea

n

Mean=0.1375

UCL=0.1378

LCL=0.1372

0.0006

0.0004

0.0002

0.0000

Ran

ge

R=1.60E-04

UCL=5.24E-04

LCL=0

151050


0.1376

0.1374

0.1372

Subgroup Number

Val

ues

0.1400.136


III

III

IISpecif ications

Within

Overall

0.137700.137450.13720

Normal Prob Plot

0.137700.137450.13720


WithinStDev:Cp:Cpk:

0.00014224.693.55


0.00019153.482.64

Process Capability Sixpack for .140(100%R)


Regrind

151050

0.0072

0.0070

0.0068

0.0066

Xbar and R Chart

Subgr

Mea

n

1

Mean=0.006941

UCL=0.007158

LCL=0.006723

0.00045

0.00030

0.00015

0.00000

Ran

ge

R=1.16E-04

UCL=3.78E-04

LCL=0

151050


0.0070

0.0068

0.0066

Subgroup Number

Val

ues

0.010.00


III

III

IISpecif ications

Within

Overall

0.007100.006850.00660

Normal Prob Plot

0.007100.006850.00660


WithinStDev:Cp:Cpk:

0.000102616.24 9.94


0.000118614.05 8.60

Process Capability Sixpack for Parallel(100

-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-Cont’d.

-Analyze-Cont’d.

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-Cont’d.

-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

Customer’s 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 Customer’s 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.

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...