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Project Title : Reduction Torn Defect at 1J line

Process Owner: AK
Green Belt: DS
Sigma Trac ID # : 200601193715

Project Schedule
Plan
Completion

Definition:
Measure:
Analyze:
Improve:
Control:
Validation:
1

Date

Actual
Completion Date

16/02/06
16/02/06
08/04/06
08/03/06
31/05/06
23/05/06
23/06/06
05/07/06
28/07/06
29/09/06

CI Statement of Work
Date printed:

Project Charter/Statement of
Work

5/15/06

Form rev.: 2006_0202a

Project Title:

BB 2006 - J CAI CPPM : Reduction of Door Panel torn defects

Location:

Malaysia - KL

Phase

Analyze

Project #

200601193715

Type:

Black Belt

Originator:
Customer Quality Focus:
Create Date:

J amilah Haron
No
2/2/06

Rollout Type:

Standard
#N/A
#N/A
2.00601E+11

Process: 1J line for door trim

Deliverable: Usable door trim

PROJ ECT DESCRI PTI ON


Process / Product
1J line process for Door Panels
Being I mproved:

Y1= CPPM for door trim (torn defect)

Project Scope and


Boundaries:

J CAI Door Panels

Customer Y (s):

Quality

Business Y (s):

Quality

Problem: 90pieces Door trim was send back to JCI


due to torn defect. This jeopardizes JCI
To reduce torn defect 70%
supplier ranking at Proton

Problem Statement: 90 pieces of door panels are returned to J CAI due to torn caused by hitting
delivery rack
Project Objective /
Suspected Root
Cause:
Primary BBP metric 4 - Scrap and I nv Loss Per EQU
impacted:
BBP Product Line:
I nteriors: Door Panels

Objective: Reduce number of defects by 70%

ESTI MATED SAVI NGS (from COPQ)

Est. Hard Savings:

23

Est. Soft Savings:

TEAM
Process Owner:

Azhari Kayoon

Black Belt:

CI Manager:

Mohd I brahim Packeer

Green Belt:

Dewa Shahril MohdNamsah

2 (b)

Measurement System Analysis


Validate measurement System
Date of study:
Reported by:
Name of product:
Misc:

Assessment Agreement

Within Appraisers
95.0% CI
Percent

95

95

90

90

85

80

75

75
2
Appraiser

Measure

85

80

95.0% CI
Percent

100

Percent

Percent

100

Appraiser vs Standard

2
Appraiser

Cost of Poor Quality


Number of reject: 246 pieces/3month (Jan 06 Mar 06)
Price for 1 piece of 1J Door Trim = RM 170.68

Defne

Cost Of Poor Quality:


246 X 170.68 = RM 41987.28/3months
Annualized Cost Of Poor Quality:
41987.28 X 4 = RM 167949.12
~ RM 167949 (USD 44197)

Quantify current performance and


estimate improvement target.

Process Sigma Level

P Chart of Return Rejec (Torn)

Proportion

0.030

0.025

UCL=0.02574

0.020

_
P=0.01921

0.015
LCL=0.01267
0.010
0.005
1

0.000
1

Sample
Tests performed with unequal sample sizes

Measure

Sigma Level (Short-term) = 2.07

Sigma Level (Long Term) = 0.57


From z table :
Baseline PPM (Long-term) = 284,339
Estimated Improvement Target = 70%
Sigma = 2.87

Target

Process Flow

1J product line Process Flow


Supply raw
material

PP sheeting

Forming and trimming

Measure

Lamination and trimming

Assembly and Inspection

Storage and delivery

Analyze

Identify causes (Xs) of variation and defects. Potential

Causes

Analyze

Provide statistical evidence that causes are real.


Cause
Commit to improvement target for Y.

Null
Hypothesis

Alternative
Hypothesis

Data to
verify

Data
Type

Verifcation

Verification
Method

Results /
Conclusion

Cause

N
o

Potential
Cause

1.

Molding shape too


sharp

Defect ratio no
change

Defect ratio
lower

Reject
data

Attribute

1-proportion

P-value = 0.00

Yes

2.

Delivery rack too


hard/sharp edge

Defect ratio no
change

Defect ratio
lower

Reject
data

Attribute

1-proportion

P-value = 0.00

Yes

3.

Rough surface
(after trimming)

Defect ratio no
change

Defect ratio
lower

Reject
data

Attribute

1-proportion

P-value = 0.00

Yes

Install solutions and provide statistical


evidence that the solutions work.

Verifed action

Y = Torn Defect (CPPM) 1J


Action Taken = Mould shape modification

Test and CI for One Proportions

( = 0.05)

Improve

Test of p = 0.0259476 vs p < 0.0259476


95%
Upper Exact
Sample X N Sample p Bound P-Value
1
13 4016 0.003237 0.005142 0.000

Improvement is
statistically significant

Install solutions and provide statistical


evidence that the solutions work.

Verifed action

Y = Torn Defect (CPPM) 1J


Action Taken = Wrapping Rack Pillars

Test and CI for One Proportions

( = 0.05)

Improve

Test of p = 0.0671463 vs p < 0.0671463


95%
Upper Exact
Sample X N Sample p Bound P-Value
1
8 642 0.012461 022371.0 0.000

10

Improvement is
statistically significant

Install solutions and provide statistical


evidence that the solutions work.

Verifed action

Y = Torn Defect (CPPM) 1J

Improve

Action Taken = Trimming jig

11

Improvement is
statistically significant

Potential Actions
Y= Torn defect at 1J product (CPPM)
Y

Improve

Torn defect

12

Cause

Potential Action

Effective
-ness
(High/Med/
Low)

Ease to
Implemen
t (High/Med/

Cost to
Implemen
t (High/Med/

Low)

Low)

Safety
Impact
(High/Med
/Low)

Molding shape too


sharp

Modify mould shape


(more curve)

High

Med

Low

Med

Delivery rack too


hard/sharp edge

To wrap all rack

High

Med

Med

Low

Rough surface (after


trimming)

Provide trimming jig

High

High

Med

Low

Improve

13

Install solutions and provide statistical


evidence that the solutions work.

Before

Completed Action

After
Wrapped rack pillars

Install solutions and provide statistical


evidence that the solutions work.

Completed Action

Improve

Use conventional
knife

14

Before

After
Trimming Jig

Monitoring Process Y
Y = Torn Defect (CPPM) 1J
P Chart of Return reject (torn)
Oct

0.030

Apr
1

0.025

Proportion

0.020
0.015

77% reduction

0.010

Control

0.005

15

UCL=0.00444
_
P=0.00132
LCL=0

1
1

0.000
1

5
6
Sample

Tests performed with unequal sample sizes

10

Next Activities in My Project


Description of tasks

16

Who

Due date

1.

To monitor implementation of trimming jig and


wrapped rack.

Azhari

End of Aug 06

2.

To monitor CPPM trend

Dewa

End of Aug 06

Results Summary
Sigma Level (ST)

Before
2.07

After
3.10

PPM (LT)

284,339

65,522

Before
Cost of Poor Quality
(Cost Reduction)
Y1

17

= Torn defect CPPM

RM 44,197

284,339ppm (LT)

After

% change

RM 0

65,522ppm(LT)

100%

77%

Next
Steps

Issue List
Issue / Request
1

18

To ensure all rack that use is


wrapped properly.

Suggested Action

Owner

Est Due date

Monitor by production member.


Any wrapping damage need to
repair prior using.

AK

On going

Countermeasure is implemented
continuously.

To issue new FMEA for process


Control.

DS
(CI)

3rd wk of Aug 06

Trimming process is using


trimming jig

Include in ODS for tool needed.

WF
ME

3rd wk of Aug 06

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