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 in
Test That Fail?
Test Machine works correctly?
Is The Assembly
Process 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 Data
Reduce PPMs?
goal
Goal
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
yes
no
no
yes
no
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 80
Drawing 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 PPMs 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 BWs)
-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
BWs 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.2
Check Valves,
pipe plugs, adapter
assembly
Sta.1
Lubricate bodies
and cover
assembly
Sta.3
Piston open/close,
spring, cover
assembly
Sta.4
Test machine,
diaphragm assembly
and packaging

Xs
Ys
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
K
P
O
V
K
P
O
V
K
P
O
V
K
P
I
V
K
P
I
V
C= Controllable
S= SOP
N= Noise
CR= Critical
K
P
I
V
K
P
I
V
Body with check valves
Torque 170,375 in/p
Parts lubricated
Loctite/aluminum
chips Contamination


K
P
O
V
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 Product
2005
3858
387
64849
93.86
5.58
0.56
0
10000
20000
30000
40000
50000
60000
70000
SR-5 SR-2 SR-4
Product
P
i
e
c
e
s
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 PPMs is the average of 2005
total PPMs, 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
P
P
M
'
s
PPM's 2005 Base Line 249488 ppm's Goal 20000 ppm's
SR-5
PPM'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 Product
2005
3858
387
64849
93.86
5.58
0.56
0
10000
20000
30000
40000
50000
60000
70000
SR-5 SR-2 SR-4
Product
P
i
e
c
e
s
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 ppms 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 Dec
P
P
M
'
s
PPM's 2005 Base Line 249488 ppm's Goal 20000 ppm's