Page: 1 Op 390 Nipple Insertion rejects [600974]

Page: 1 Op 390 Nipple Insertion rejects
RT5 DFP3 –Volume

Page: 2 Op 390 Nipple Insertion rejects
Focus
Multiple Metrics Leveraged and Projected Impact: The project was selected from the DFP3 Pump Rolling Top 5 Matrix and
will impact bought scrap cost and FTQ.

Project Definition: Op 390 has experience a large number of rejects as a result of Nipple Insertion. Find and eliminated the
RedX causing Op 390 Nipple Insertion rejects to save € / year and leverage across like operations .

Project Tracker number:
Team Leader: Papuc Ciprian SM- 041-130426
Team Members:
Contributing Member s (Not for Certification) :
Rolling Top 5® Manager (Local Sponsor): Matei Ionut
Rolling Top 5 Executive (Executive Sponsor): Teodoru Cristian
Coordinator (If Applicable):
Coach: Panainte Cristina

Approach
Green Y® Description: Final load at nipple insertion lower than 1300 N

Strategy Selected and Best Contrast(s) Leveraged: Strategy diagram constructed are Time to time family of variation
selected. Event destructive strategy used.

Measurement System Verified: Measurement system passed Isoplot with a Discrimination Ratio = 142.4
2

Page: 3 Op 390 Nipple Insertion rejects
Converge
Converging on the Red X®: The measurement system was verify with a Kistler sensor wich was put in paralel with Ja nome
press and the DR was higher than 6 . We measured nipples from both batches. On WOW batch most of nipples were NoOK
with 5,16 diameter under lower limit specification.On BOB nipple batch all measurements was in spec. We passed
confirmation test B vs W 6 pack ,saw the Red X is Nipple diameter under lower limit.

Red X Candidate Identified:
Test
Risk Assessed and Type of Confirmation Experiment Applied: Confirmation test was passed , B vs W 6 pack.

Red X Confirmed: Nipple diameter out of spec.

Understand
Green Y to Red X Relationship Understood and if Appropriate Tolerance Limits Established: Final load at nipple insertion
lower than 1300 N is the Green Y.
The Specification for the Nipple is 5,16 ±0,1. When we make insertions with nipples under lower limits at 5,16 diameter the
final loads is less than specification.

3

Page: 4 Op 390 Nipple Insertion rejects
Apply
Corrective Action Implemented and Verified: It was made a complain to incoming and they sort 100% all nipples . They
submitted and supported all sorting costs, after they guarantied us to deliver good parts .

Corrective Action Proceduralized :

Project Duration: 23 weeks

Project Benefits and Cost Savings: Improved FTQ and saved 13333,56 euro.
Leverage

Read Across Implemented and Additional Savings Calculated: Controls read across to all references .

Lessons Learned : Project documented and communicated to the management and the supplier to prevent this.
4

Security Classification Competency Descriptor
5 WET RW
area (0.33%)
169.932 Euro DFP3 – Scrap Problem definition tree
Assy&Test&
FO
(1.24%)
634.317 Euro Pumps Injectors
DFP 3
(1.24%)
634.317 Euro DFP 6
(0.90%)
43.525 Euro
MACHINING
(0.66%)
340.282 Euro Rationale:
• Big problem is in
pumps area
• Biggest amount of
many lost are in DFP3
pumps
• 0.43% generated by
the CR RW area Preassembly
Area (0.18%)
90.582 Euro Paint RW
Area (0.30%)
153.876 Euro • Major contribution to
scrap value is add by A
&T&FO
Project statement: Find and kill Red X causing % scrap in
WET RW area. Problem Statement: Reduce the
scrap value less then 1% overall
until end of 2012
IV
(0.01%)
7.289 Euro PLV
(0.08%)
40.114 Euro
CR RW
Area (0.43%)
219.927 euro HT DFP3
(0.34%)
174.702 Euro
FACTUAL™ FOCUS

Security Classification Competency Descriptor
6 WET RW
area (0.33%)
169.932 Euro Preassembly
Area (0.18%)
90.582 Euro Paint RW
Area (0.30%)
153.876 Euro CR RW
Area (0.43%)
219.927 euro
Helium
(0.02%)
10.640 euro Insertions
(0.25%)
129.452 euro RW online
(0.01%)
5.498 euro Others
(0.15%)
74.336 euro
Ball Insertions
PL Dan Varlan
(Ramon
G)(0.09%)
46.602 euro Nipple
Insertions
(Papuc
Ciprian)
(Ramon G)
(0.04%)
22.006 euro Venturi plug
Insertions
(Alin
Costea)(0.09
%) 46.602
euro Regulator
plug
Insertions
(Bogdan
Chirila)(0.03%)
12.945 euro DFP3 – Scrap Problem definition tree:
• Biggest area which
generate scrap is Dry
Rework, in CR
• In CR the biggest scrap
reject are insertions from
Subassembly FP
•From all insertions in
Subassembly FP, Ball
Insertions and Venturi
Plug Insertion are the
biggest issue
FACTUAL™ FOCUS

Page: 7 Op 390 Nipple Insertion rejects
Project Definition Tree
Rationale:
•Higher reject rate is on HMC-A reference FACTUAL™ Approach Project statement: Find and kill Red X causing Front Plates rejects at OP 390.
7 •We use energy to press the nipple in Front Plate.
•It is an event destructive because , after pressing the
part can’t be reworked , it is scrap.

Green Y Final load at nipple insertion lower than 1300 N
•Most rejects are at low final load •We cut the position because this problem it was
solved with a PAA nr. where was increased the
position Pfin. min. 4.5 to 4.7mm and Pfin.max
5,1 to 5,7mm.so the biggest problem remain
load. OP 390 nipple
insertion reject
002 009/011 012
Initial
Low Final Event Defect Feature
Distructive Malfunction Property
Load Other Position
High
The final load is
measured at 3 mm
from touching
point

Page: 8 Op 390 Nipple Insertion rejects
Process flow diagram
Buffer Inputs Operation
Function
•Fp from operation 391

•Nipple handling

•Tag identity

•Machine fixture(depends of
references)

•Press electric(control speed ,
acceleration)
•Force , position

•Tag orientation Poka Yoke
•Program by application •Insert the nipple
at a fix
position/force and
control them

•Act as traceability
Poka Yoke

Reject parts , go to scrap
OP 390
Nipple insertion Nipple press Tag reading
Tag writing Washing
machine DURR Washing machine
Megadurr
OP 391 insertion conector
venture(oiled parts)
•The risk is oil all nipple
with hand, because
operator work with oil OP
391

Page: 9 Op 390 Nipple Insertion rejects
9 What is meant by each contrast Diagram
Point to Point
Same nipple insertion
Don’t know Large contrast
Small or no contrast
N/A
Nipple insertion to
Nipple insertion
Same Fp references FACTUAL™ Approach Event Destructive Strategy Diagram
Same Line Fp references to Fp
references Contrast
•We don’t have suddenly variation
between point’s
•We use this type of nipple for 2
references of pumps(hmc-a/hmc-
u)and both have almost the same
rate of reject
•We have high contrast because
we have OK and NOOK
insertions
Green Y Final load at
nipple insertion lower
than 1300 N

Page: 10 Op 390 Nipple Insertion rejects
10 What is meant by each contrast Diagram Don’t know Large contrast
Small or no contrast
N/A FACTUAL™ Approach Event Strategy Diagram
Line to Line Contrast
Time to Time Same Time •We made reference HMC-A in both
lines ,and the reject rate is almost
the same
•Time to time we have high
contrast , this means batch to
batch nipple .We had batch’s with
a lot of rejects and when we
change the batch we have no
reject.
Green Y Final load at
nipple insertion lower
than 1300 N

Page: 11 Op 390 Nipple Insertion rejects
11 Solution tree
Rationale: FACTUAL™ – Converge
Delta P Delta M
Process Parts
Front Plate Nipple •The measurement system was verify with a Kistler
sensor wich was put in paralel with Janome press and
the DR was higher than 6
•With the same batch of Front plates and batch of
nipples in L1 and L2 we had similar rate of rejects
•In the same time for the same batch of FP we use
nipple from one batch which give us a lot of reject with
low force, we changed the batch of nipples and we
increase the force
Ø5,16±0,1 Other •We measured nipples from both batches. On WOW batch
most of nipples were NoOK with 5,16 diameter under
lower limit specification.On BOB nipple batch all
measurements was in spec

•We passed confirmation test B vs W 6 pack Nipple diameter under lower limit
Green Y Final load at
nipple insertion lower
than 1300 N

Page: 12 Op 390 Nipple Insertion rejects
The measurement system is Ok , isoplot passed with a Discrimination Ration =142,4 more than 6 which is normal
for an event strategy. ISOPLOT

Page: 13 Op 390 Nipple Insertion rejects
Action: We took 50 nipples from normal production WOW time high rate of rejects and 50 nipples from an old batch
from BOB time no rejects at insertion and we inserted them on the same batch of front p lates. We inserted these
nipples randomly from both batches.
Conclusion:
After insertions we saw that the old batch of nipples ( BOB time) had moved up the final loads distributions than current
nipple batch ( WOW time).From Multi Vari we saw a clearly separation between batchee s.
Red X lies in nipples . We sent to measure nipples from current ( WOW) and old batch (BOB). Batch to batch contrast

Page: 14 Op 390 Nipple Insertion rejects
We see a clearly separation between Bob batch of nipples and Wow batch of nipples , so we
can say that the Red X candidate is the diameter Ø 5,16 ± 0,020 . Comparison between BOB and WOW batches of nipple

Page: 15 Op 390 Nipple Insertion rejects
FACTUAL™TEST
Conclusion : We took the 3 nipples at the nominal value on 5,16 diameter(BOB) and 3 nipples out of spec
(WOW) with lower diameter . We inserted them into the FP and we measured the force . For the BOB
nipples we had higher final loads than WOW nipples insertions. All WOW insertions had final loads bellow
lower limit.
We passed confirmation test B vs W 6pack
LSL USL Confirmation test B vs W 6 pack

Page: 16 Op 390 Nipple Insertion rejects
Conclusions
FACTUAL™Understand
This
dimension is
out of spec Ø5,16±0,1
When we make insertions with nipples under lower limits at 5,16 diameter the final loads less than
specification

Page: 17 Op 390 Nipple Insertion rejects
P-CHART
In week 36 was made a complain to incoming and they sort 100% all nipples . They submitted and supported all sorting
costs, after they guarantied us to deliver good parts

Page: 18 Op 390 Nipple Insertion rejects
Savings
Savings for 2 month are 13330.56 euro.