MH Los Arcos - Grupo Industrial La Italiana S.A. de C.V. Nombre Departamento.
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Transcript of MH Los Arcos - Grupo Industrial La Italiana S.A. de C.V. Nombre Departamento.
Título del proyectoMH Los Arcos - Grupo Industrial La Italiana S.A. de C.V.
Nombre
Departamento
Fase del proyecto
Fecha de inicio Fecha propuesta de finalización
Fecha real de finalización
Definición 01/04/2011 05/04/2011 05/04/2011
Medición 05/04/2011 10/04/2011
Análisis 11/04/2011 18/04/2011
Mejora 19/04/2011 30/04/2011
Control 01/05/2011 13/05/2011
Validación
Scheduling
Imagen relacionada con el proyecto Planta: Los Arcos
Process Owner: ----------Proceso:
Nombre del proyecto
D M CA I
Declaración del problema
Cuantificar…
Imagen relacionada con el proyecto
Imagen relacionada con el proyecto
D M CA I
Objetivo del proyecto Eliminar… Garantizar… Reducir…
Imagen relacionada con el proyecto
Imagen relacionada con el proyecto
D M CA I
Primer paso
Segundo paso
Tercer paso
Cuarto paso
yb: costo…
yp: paquetes con defectos
Proceso
D M CA I
y’s y validación del SM
YC1= ------------- (MXN)
YB1 = ----------- (PPM)
YB2 = ----------- (USD)
YP1= ---------------- (m)
YP2= ----------------- (PPM)
YP3= ---------------- (PPM)
Observation
Indiv
idual V
alu
e
10987654321
10
5
0
_X=3.4
UCL=9.61
LCL=-2.81
Observation
Movin
g R
ange
10987654321
8
6
4
2
0
__MR=2.333
UCL=7.624
LCL=0
I-MR Chart of Num piezas
YB1: ------ (MXN)
Calibration certificate (Destructive Test) Dimensional Report
for Gage GO / No GO
YP1= Push out force (Nw)
YP2= Burrs presence (PPM)
YP3= Deformed bushing (PPM)
Attribute MSA accepted
D M CA I
Análisis de capacidadyp1: ------------------
Nivel Sigma: -0.51
DPMO = 696279 PPM
D M CA I
Análisis de capacidad
Descripción Antes Target Después % mejoraYC YC1: SDDSDVSV 2000 0
YB YB1: OIDHJSDN 125 0 YB2: IAJASDOndcjknc 12580 0
YP
YP1: JSONJdnc
yp11: spagh Avg 135 > 200 PPM 7850000 4 Sigma 0.3 6
yp12: fideos Avg 135 > 200 PPM 7850000 4 Sigma 0.3 6
YP2: UIHDCNSDSCAvg 135 > 200 PPM 7850000 4
Sigma 0.3 6
D M CA I
Identificación de causas (X’s)YP1= Push out force (Nw)
Push out force under spec
Materials Method
People Machines
Non defined frequency of
electrode change
The way in which the piece is placed isn’t
always the same
Non defined welding parameters
Materials are not fixed correctly
Variation in the thickness of the plate
Operators aren’t trained
Personnel rotation
Reworked electrodes
First shift operators use a different method than those of the third shift
X1
X2
X3
Push out force under spec
Materials Method
People Machines
Non defined frequency of
electrode change
The way in which the piece is placed isn’t
always the same
Non defined welding parameters
Materials are not fixed correctly
Variation in the thickness of the plate
Operators aren’t trained
Personnel rotation
Reworked electrodes
First shift operators use a different method than those of the third shift
X1
X2
X3
YP2= Presence of burrs
Burrs on bushing
Materials Method
Non defined frequency of
electrode change
The way in which the piece is placed isn’t
always the same
Variation in the thickness of the plate
First shift operators use a different method than those of the third shift
Materials are not fixed correctly
People Machines
Non defined welding parameters
Operators aren’t trained
Personnel rotation
Reworked electrodes
X1
X2
Burrs on bushing
Materials Method
Non defined frequency of
electrode change
The way in which the piece is placed isn’t
always the same
Variation in the thickness of the plate
First shift operators use a different method than those of the third shift
Materials are not fixed correctly
People Machines
Non defined welding parameters
Operators aren’t trained
Personnel rotation
Reworked electrodes
X1
X2
YP3= Deformed bushing
Bushing deformation
Materials Method
People
Non defined frequency of
electrode change
The way in which the piece is placed isn’t
always the same
Misaligned Electrodes (concentricity)
Variation in the thickness of the plate
First shift operators use a different method than those of the third shift
X6
X7
Electrode holder notperpendicular to base
Electrode holders are not parallel
X4
X5
Materials are not fixed correctly
Machines
Bushing deformation
Materials Method
People
Non defined frequency of
electrode change
The way in which the piece is placed isn’t
always the same
Misaligned Electrodes (concentricity)
Variation in the thickness of the plate
First shift operators use a different method than those of the third shift
X6
X7
Electrode holder notperpendicular to base
Electrode holders are not parallel
X4
X5
Materials are not fixed correctly
Machines Causas potenciales:
X1 – Non defined welding parametersX2 – Reworked electrodesX3 – Different Method between ShiftsX4 – Electrode not parallelX5 – Electrode not perpendicularX6 – Misaligned electrodesX7 – Method to place piece in welder
D M CA I
Validación de causasX6Misaligned electrodes (concentricity) YP3
1 sample-t
6 measurements around electrodes pulled together
One-Sample T: concentricity Test of mu = 90 vs not = 90 Variable N Mean StDev SE Mean 95% CI T P concentricity 6 89.9500 0.0548 0.0224 (89.8925, 90.0075) -2.24 0.076
Ho: the angle at which electrodes are pulled together is 90°
Ha: the angle is different to 90°
Electrodes are not misaligned
Electrodes are not misaligned
Null hypothesis is not rejected
D M CA I
Matriz de causas verificadas
Ys Potential Cause Null Hypothesis Alternative Hypothesis Verification Data Data type Verification method P- value Significant?
X1Non defined welding
parametersn/a n/a DOE Variable DOE n/a ?
Pressure n/a n/a DOE DOE n/a ?Weld time n/a n/a DOE DOE n/a ?
Heat n/a n/a DOE DOE n/a ?Hold time n/a n/a Fixed on DOE Fixed on DOE n/a No
Squeeze time n/a n/a Fixed on DOE Fixed on DOE n/a No
X2Reworked electrodes
Detachment force is the same with new or excessively reworked
electrodes
Detachment force is different with new or
excessively reworked electrodes
5 pieces for 3 mm- reworked electrodes,
and 5 for 5 mm- reworked electrodes
Variable 2 sample-t 0.002 Yes
YP1 X3
First shift operators use a different method
than those from the thrid shift
Pieces welded by workers from shifts 1
& 3 have same detachment
Pieces welded by workers from shifts 1 &
3 have different detachment
4 pieces welded by worker 1 and 4
pieces welded by worker 2 (3rd shift)
Variable 2 sample-t 0.915 No
X4Electrode holders are
not parallel
Superior measurement equals inferior measurement
Superior measurement different to inferior
measurement
6 different points around electrode holders, match
superior to inferior
Variable Paired t test 0.695 No
X5Electrode holder not
perpendicular to base
Electrode holder angle equals 0° (is
perpendicular)
Electrode holder angle is different to 0°
6 measurements Variable 1 sample t0.203 & 0.102
No
X6Misaligned electrodes
(concentricity)
The angle at which electrodes are pulled
together is 90°
The angle is different to 90°
6 measurements around electrodes
pulled togetherVariable 1 sample t 0.076 No
X7The way in which the piece is placed isn't
always the same
Angle at which the device is held is not
modified (=0°)Angle different to 0°
15 measurements during welding (greatest angle
taken)
Variable 1 sample t 0.00 Yes
YP3
YP1 & YP2
X1 DOE
X2 & X7 verified significant
X3, X4, X5, & X6 verified not significant
X1 DOE
X2 & X7 verified significant
X3, X4, X5, & X6 verified not significant
D M CA I
Matriz de mejoras
Very effective, easy to implement, low cost
Moderately effective, Moderately easy to implement, Moderate costNot very effective, Hard to implement, High cost
LEGENDYsPossible
Counteractions
Efe
cti
ve
ne
ss
Ea
sy
to
Im
ple
me
nt
Co
st
Sa
fety
YP1 X1Non defined welding
parameters
Establish optimal parameters by DOE (analysis focused on
push out force)
YP2 X2Reworked electrodes
Calculate useful life of electrodes (durability)
YP3 X7
The way in which the piece is placed
isn't always the same
Install a pokayoke so that when the device is placed, there is no way
the angle varies and affects the electrodes
asymetrical wear down and bushing deformation
Potencial Causes X's
Conteractions:
X1 – Establish optimal parameters through DOE
X2 – Define the useful life of electrodes
Soluciones
Análisis por ANOVA, DOE Factorial, Superficie de Respuesta, CDC, etc…
D M CA I
D M CA I
Controles
“Welding Parameters Register” form updated. Parameters are audited every 14 days.
HOJA DE REGISTRO DE PASOS Y PARAMETROS DE PUESTA A PUNTO
CODIGO DEL EQUIPO: PUP-01OPERACIÓN: A4ADAP 120/AD 120/A4AD 120DESCRIPCIÓN OPERACIÓN:PUNTEADO DE BUJES A CACHAS
INDICAR LOS RANGOS DE PARAMETROS COMO EVIDENCIA DE LA PUESTA A PUNTO.
Característica Rangos de Parámetros Registrar valores obtenidos en la Puesta a Punto del Equipo de la Celda de Trabajo.
OK Colocar OK en cuadro correspondiente si el paso de la descripción de Puesta a Punto se realizó.NOK Colocar NOK en cuadro correspondiente si el paso de la descripción de Puesta a Punto no se realizó, y colocar en el cuadro de observaciones la Razón por la cual no esta OK.N/A Colocar N/A en caso de que la Celda de Trabajo no esté operando.
Paso 1.- Verificar llaves de agua abiertas
Paso 2.- Encender la maquina
Paso 3.- Verificar que no tengan paros de emergencia
Paso 4.- Verificar los electrodos de la punteadora.
Paso 5.-Verificar que el botón del controlador este en WELD y en ON.
NIVEL FECHA DESCRIPCIÓN DEL CAMBIO REVISÓ: APROBÓ:1 6.09.02 CAMBIO DE FORMATO2 25.11.03 CAMBIO DE FORMATO
N/A
Nota: ante cualquier anomalia en la puesta a punto de tu operación debes para y avisar a tu supervisor de producción.
ASIENTO DELANTERO A4/NB
OBSERVACIONES
N/A
Llaves de agua abiertas
Estado de los electrodos
DESCRIPCIONES DE LA PUESTA A PUNTO
Supervisor de Producción Spervisor y/o auditor de Calidad.
SI NO
ITEM DE CONTROL
D
“Set up sheet” now includes the parameters at which the machine should be working.
D M CA I
Medición posterior a las mejoras
Data
A4 fijo despuésA4 antes
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
Boxplot of A4 antes, A4 fijo después
Two-Sample T-Test and CI: A4 antes, A4 fijo después Two-sample T for A4 antes vs A4 fijo después N Mean StDev SE Mean A4 antes 28 3101 1735 328 A4 fijo después 10 8001 926 293 Difference = mu (A4 antes) - mu (A4 fijo después) Estimate for difference: -4900.13 95% upper bound for difference: -4154.25 T-Test of difference = 0 (vs <): T-Value = -11.15 P-Value = 0.000 DF = 30
95% Bonferroni Confidence Intervals for StDevs
A4 fijo después
A4 antes
2500200015001000500
Data
A4 fijo después
A4 antes
1000080006000400020000
F-Test
0.032
Test Statistic 3.51P-Value 0.053
Levene's Test
Test Statistic 5.00P-Value
Test for Equal Variances for A4 fijo antes, A4 fijo después
Test for Equal Variances: A4 fijo antes, A4 fijo después 95% Bonferroni confidence intervals for standard deviations N Lower StDev Upper A4 antes 28 1327.95 1734.66 2475.43 A4 fijo después 10 605.41 925.53 1863.70 F-Test (normal distribution) Test statistic = 3.51, p-value = 0.053 Levene's Test (any continuous distribution) Test statistic = 5.00, p-value = 0.032
Sample
Sam
ple
Mean
18161412108642
10000
7500
5000
2500
0
__X=8001
UCL=10078
LCL=5923
A4 antes A4 fijo después
SampleSam
ple
Range
18161412108642
6000
4500
3000
1500
0
_R=1105
UCL=3609
LCL=0
A4 antes A4 fijo después
Xbar-R Chart of Datos A4 fijo by Etiq2
D M CA I
Nuevos niveles Sigma
Descripción Antes Target Después % mejoraYC YC1: SDDSDVSV 2000 0
YB YB1: OIDHJSDN 125 0 YB2: IAJASDOndcjknc 12580 0
YP
YP1: JSONJdnc
yp11: spagh Avg 135 > 200 PPM 7850000 4 Sigma 0.3 6
yp12: fideos Avg 135 > 200 PPM 7850000 4 Sigma 0.3 6
YP2: UIHDCNSDSCAvg 135 > 200 PPM 7850000 4
Sigma 0.3 6