Body 294837 with seat valve damaged

Thought Process Map

Why Are Rejected The Valves?

Is The Raw Material good to assembly ?

Are The Material Involved inTest That Fail?

Test Machine works correctly? Is The AssemblyProcess Reliable

Are The Test Step Within Specification?

Are The Parts Assembled Correctly ?

Are The Parts Contaminated or Damaged?

Implement a Change or Improve in the Process

Implement Solution for Material Involved in Rejects

Verify DataReduce PPM’s?

goalGoal

MEASURE

ANALYZE

IMPROVE

CONTROL

Are The Parts Within Spec?

Relation Between the Failed Tests and the Material Specification Exists ?

Data Indicates That The Machine is Failing?

yes

no

yes

no

Some Test Step Exists That Fails Continuously

yes

no

no

yes yes

yesno

no

yesno

yes

Data Indicates That The Material is Reject Root Cause?

no no

yes

yes

no

no

yes

Implement Solution for Test Machine

no

yes

yes

no

yes

no

yes

no

yes

no

Test # 4 failed by bad body

Seat valve without spec finished 80Drawing 294837

DOE shows that 97.66% of rejects is caused by body seat valve damaged

Action Plan was implemented with supplier for parts certified

Improvement PPM’s of 256663 to 24066 or 90%

SIPOC

SUPPLIERS•- SQA Receipt Inspection (Mainframe QC10 instructions) •-Materials Dept.•-Machining Area•-Twist Inc •-Parker Hannifin•-Sun Strong Precision•-Asimco( 294837 body certified) •-H R Dept.•-Engineering Dept.•-H S & E Dept

PROCESS:SR-5 Valve Production

-Valves Assembly(assembled appropriate with good bodies)-Valves Tested-Valves Packaging

CUSTOMERS ( & requirements)

•-Production Planners•-Shipping Dept. (DON)•-Q.C. Dept. (Make parts by BW’s)•-On Time Delivery (DON)•-Mccoy Brothers•-Great Dane Trailers •-Deloupe Inc.•-Cottrell Inc•-Fountaine Trailer Co.•-Reitnover Inc.•-Trailmobile Canada Inc.

INPUTS OUTPUTS

•-Assembly Product on Time •-Spec BW-486-T Rev 4•-Assembly Complete•-Correct Packaging (Qty)•-Appropriate Identification ( Part Number)•-Correct Components•-Contamination Free•-Free Accidents Process

•-Materials within BW’s Specifications (Body 294837 .218 dia) •-Trained Operators•-Lubricated parts•-Control Documents•-Pressure Air•-Electricity•-Test Process (Program Adequate)•-Assembly Fixtures and Tools (Clutch Tools)•-Safety Norms

Process Map (Entradas /Salidas)

Sta.2Check Valves,

pipe plugs, adapter assembly

Sta.1Lubricate bodies

and cover assembly

Sta.3Piston open/close,

spring, cover assembly

Sta.4Test machine,

diaphragm assembly and packagingX’s Y’s

• C- Lubrication BW-650-M • CR-Materials (spec.)• C-Torque tool • C-Loctite BW-621-M• C- Air Pressure• CR-Impact tool•SOP-Instructions • C-Training Operators

•Subassy Body/Cover•Contamination free•Torque 120 in/p•Blow off parts•Parts Lubricated

• CR-Materials (spec.)• C-Torque tool• C-Loctite BW-621-M • C-Lubrication BW-650-M• CR-Impact tool•SOP-Instructions• C-Training Operators

• CR-Materials (spec.)• C-Torque 20 in/p • C-Fixture for assembly• C-Lubrication BW-650-M•SOP-Instructions• C-Training operators

KPOV

KPOV

KPOV

KPIV

KPIV

C= Controllable S= SOP N= NoiseCR= Critical

KPIV

KPIV

•Body with check valves•Torque 170,375 in/p•Parts lubricated•Loctite/aluminum chips Contamination

KPOV

•Valve assembly•Torque 20 in/p•Parts lubricated

•Valve tested•Leak <200 sccm•Parts lubricated•Parts rejected test #4

•SOP-Test specifications BW-486-T• CR-Pneumatic System• CR-Measurement instrument• C-Valves assembled• CR-Preventive Maintenance•SOP-Instructions• C-Training operators• C-Air Pressure

Variable Target Control

Material spec.(Body294837) .218 dia. , 80 microinch surface finished

nothing

Pipe plugs assembled contamination free Depends of operator

Test Machine Parker valves contamination free Depends of technician

: Baseline Statistics

Tested Pieces by Product2005

3858 387

6484993.86

5.58 0.56010000200003000040000500006000070000

SR-5 SR-2 SR-4

Product

Piec

es

0.00

20.00

40.00

60.00

80.00

100.00

%

tested pieces %

In the SR-5 Line, three different products are assembled (SR-5, SR-2, SR-4) , the 93.86% of these parts are of SR-5, for this reason we worked with this product

Product 

Year 2005 tested pieces %

SR-5 64849 93.86

SR-2 3858 5.58

SR-4 387 0.56

Baseline Statistics

249488 PPM’s is the average of 2005 total PPM’s, it is the baseline to measure the project advance improvement

FTTSF Line SR-5 2005

0

50000

100000

150000

200000

250000

300000

350000

400000

Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec

PPM

's

PPM's 2005 Base Line 249488 ppm's Goal 20000 ppm's

SR-5PPM's 2005

Base Line

249488 ppm's

Goal 20000 ppm's

Jan 283738 249488 20000

Feb 352646 249488 20000

Mar 296490 249488 20000

Apr 258973 249488 20000

May 291596 249488 20000

Jun 265865 249488 20000

Jul 209520 249488 20000

Aug 267037 249488 20000

Sept 254695 249488 20000

Oct 144774 249488 20000

Nov 180881 249488 20000

Dec 187637 249488 20000

Graphical Methods

Tested Pieces by Product2005

3858 387

6484993.86

5.58 0.56010000200003000040000500006000070000

SR-5 SR-2 SR-4

Product

Piec

es

0.00

20.00

40.00

60.00

80.00

100.00

%

tested pieces %

Charts to determine the most important product and the base line•SR-5 is 93.86% of total production on the line•249488 ppm’s is the base line (2005 average)

FTTSF Line SR-5 2005

0

50000

100000

150000

200000

250000

300000

350000

400000

Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov DecPP

M's

PPM's 2005 Base Line 249488 ppm's Goal 20000 ppm's