Line 100 High Plunge FACTUAL Project 020808

Problem Definition Tree
High Plunge - Line 100
Dana AH
FACTUAL - Focus
Rationale:
Rolling Top 5 Rolling Top 5 Single Metric Rolling Top 5 Scrap Summary Report
New Technology Trouble-free (scrap) Reliability - March 07
Launches $138K/Month
Other value streams Line 90 Line 110 Line 100 Scrap Summary Report by Line - March 07
< than 15K per line 20K 28K 43K
Other failures Runout Flip Slip/Plunge Scrap Summary Report by Defect - Line 100
< than 3K each 5K Balance Effort
11K $17K
Other base p/ns 5010880 5010867 Scrap Summary Report by Part - Line 100
< than 1K each base p/n base p/n
4K $9K
Project Statement: Find & eliminate the Red X driving high plunge force on base part number 5010867 on line 100
to save approximately $9K/month in scrap costs.
File Name: Line 100 High Plunge FACTUAL Project 020808.ppt Page: 1 Project Date: 03/12/2007
Copyright 2004, Red X Holdings LLC. All rights reserved.
See www.shainin.com for a complete listing of Trademark and Copyright information. Template Revised: July 5, 2004 CONFIDENTIAL
Scrap Summary Report - March 07
Scrap Summary Report by Line - March 07
Scrap Summary Report by Defect - Line 100
Scrap Summary Report by Part - Line 100
LINE: 100 From: 3/1/2007 To: 4/1/2007
Pareto Chart - High Plunge Scrap Cost ($) by P/N
$6,000
$5,000
$4,000
$3,000
$2,000
$1,000
$0
5010867-1 5010867-2 5010880-1 5010880-3 5010881- 5010867-5
108M
Project Definition Tree
FACTUAL - Approach
Project Statement: Find & eliminate the Red X driving high plunge force on base part number 5010867 on line 100
to save approximately $9K/month in scrap costs.
Rationale:
Event Defect Feature Property Problem is a malfunction event
Marry-up Other Plunge force can only be measured at marry-up

Rejects Rejects operation
Plunge force measured Plunge force measured Vehicle mounting position determined by customer
at mid-slip position at different positions
Perforamance Distribution
Customer Spec (35 lb max.)
REQUIRED
CURRENT
0 20 40 60 80 100
Force (lb)
Solution Tree
Perforamance Distribution
FACTUAL - Converge
Customer Spec (35 lb max.)
Green Y = Plunge Effort (lbs)

Plunge effort is the compression and
REQUIRED
CURRENT extension force measurement of the slip-in-
tube driveshaft.
0 20 40 60 80 100
Force (lb)
Rationale:
P M Isoplot: DR = 6.4 (passed test)
Other failure Forensic evidence showed large quantity of foreign

Foreign Material
modes material (FM) attached to both inner and outer tubes
Pareto: majority of FM were weld beads. Foreign material

source
Weld beads Other FM Foreign Material and spline damaged #1 thru #6
Size ranged from 0.46mm (.018) to 2.79mm (.109)
Concentration Diagram
Inner/outer tube Other locations
spline interface
Confirmation Test: Plunge force before & after
Both BOB/WOW have FM, however location creates
WOW plunge
RED X Weld bead location in relation to spline interface
Isoplot
Foreign material source
Foreign Material Source
35
29
30
25
# of pieces
20
15 13
9
10
5
5
0
Weld beads Plastic chips Carboard paper Other
Concentration Diagram
WOW Location BOB Location
Confirmation Test: Plunge force before & after
Plunge Force Before & After Tear Down Inspection
90
76 79
80 70
70 61 64 62
Plunge force (lb)
55 57
60
50
40 Spec = 35 31 34 33
25 28
30 24
20 15 18
10
0
BOB1 WOW1 WOW2 WOW4 WOW5 WOW6 WOW7 WOW3
Original Plunge Plunge after foreign material removed
Part with weld bead pushed in the inner tube and material still attached to it
Failure mode not able to be removed from this part.
Foreign Material and spline damaged #1
WOW3
inner
tube
weld bead
pushed in
the spline:
WOW3
inner
tube
weld bead
magnified:
WOW6
outer
tube
spline
scratch:
Corrective Actions
a) Replace welder splatter guards more frequently (once/day vs. when its damaged). Resp.: Kevin York. Due date: 3/16/07
b) Investigate improved/more robust material for splatter guard to decrease the change frequency. Resp.: Marcelo Lavigne.
Due date: 3/20/07
c) Modify air blower setup at welder to increase the pressure and expel all loose weld beads from the parts. Implement usage
of this equipment on both inner and outer tube welders. Resp.: Barry Kerska. Due date: 3/21/07
d) Change conveyer system to prevent FM from the conveyer to be lodged in the spline area. Resp.: Barry Kerska. Due date:
4/30/07
e) Eliminate usage of buffer cart at marry-up operation on JK front shafts to prevent additional FM (cardboard, plastic, etc.)
from getting into the spline area. Resp.: Cal Smith. Due date: 3/16/07.
Executive Summary - FACTUAL
Focus
Multiple Metrics Leveraged / Projected Impact: Scrap cost impact for this issue on line 100 was $11,292 in Feb 07 and
$17,373 for Mar 07.
Potential Read Across: Overall plant scrap cost for high plunge in Feb 07 was $16,013 and $24,246 for Mar 07.
How Was Project Selected? (Was Pareto Found Through Multiple Metric Rolling Top 5 ?): Problem was originally
witnessed during scrap review meeting held on 3/7, where an excessive amount of parts were found in the scrap bin from the
previous night (3rd shift) and continued throughout the 1st shift. This issue was the 3rd highest scrap contributor in Feb 07
and quickly became the top contributor for scrap during the month of March.
Project Definition: Investigate cause of scrap generated on line 100 due to high plunge exceeding customer specification
Staffing Matrix: Project Leader Marcelo Lavigne

Team Members Marcelo Lavigne
Contributing Members - Danielle Collins; Lon Lundquest
Rolling Top 5 Manager (Local Sponsor) - Marcelo Lavigne
Rolling Top 5 Executive (Executive Sponsor) Ravi Dodaballapur
Coach Perry Chron
Executive Summary - FACTUAL
Approach
Physical Nature of Green Y Understood: Plunge effort is the compression and extension force measurement of the slip-in-
tube driveshaft.
Plunge Effort = Force to collapse / extend shaft
Strategy Selected / Strategy Diagram Developed:

a) Segregate 5 WOWs and 5 BOBs
b) Determine the measurement = green Y = marry-up
c) Weigh parts
d) Disassembly parts
- maintain orientation of all components;
- mark each component
- remove grease and inspect for foreign material
e) Reassemble parts with no grease and no boot and check plunge
f) Reassemble parts with boot and no grease and check plunge
g) Weigh parts
Measurement System Verified: Isoplot passed acceptance criteria: DR = 6.4
Executive Summary
Converge
Contrast Identified: Forensic evidence revealed high concentration of foreign material (FM) attached in the spline area of the
WOWs. Foreign material was also observed on the BOBs, but not in the spline area. See Foreign Material and spline damaged
slides.
Best Contrast Leveraged: All WOW parts presented FM in the spline area compared to no FM in this area on BOB parts.
Converging on the Red X : Majority of FM found on high plunge parts was determined to be for weld beads. Range of sizes
for weld beads found were between 0.46mm to 2.79mm (average size = 1.18mm). See Foreign Material Source
Red X Candidate Identified: Weld beads.
Executive Summary
Test
Risk Assessed: 5% or 1/20 using 5 penny test.
Confirmation Experiment Applied: 6 out of 7 WOWs were able to be salvaged by removing the FM from the spline area. The
plunge force delta average on the WOW parts was -33.6 lbs. See Plunge force before & after tear down inspection
Red X Confirmed: 5 penny test: plunge force reduced when weld beads in the grob spline area were removed.
Executive Summary
Understand
Green Y to Red X Relationship Understood: FM in the grob spline area will negatively impact slip in tube plunge force.
Executive Summary
Apply
Corrective Action Implemented:
a) Replacement of welder splatter guards at a higher frequency (once/day vs. when its damaged). April 07.
b) Introduced usage of improved/more robust material for splatter guard to decrease the change frequency. April 07.
c) Increased pressure of air blowers welder to increase the pressure to expel all loose weld beads from the parts. May 07.
d) Eliminated usage of buffer cart at marry-up operation to prevent additional FM (cardboard, plastic, etc.) from getting into
the spline area. June 07.
Effectiveness of Corrective Actions Verified: Green Y Run Chart:

Line 100 High Plunge Scrap
$20,000 Fixes/solutions put in place

Corrective
$18,000 Action Proceduralized:
$16,000
Project Duration:
$14,000
Cost Savings Calculated:
$12,000
$10,000
$8,000
$6,000
$4,000
$2,000
$0
Jan- Feb- Mar- Apr- May- Jun- Jul-07 Aug- Sep- Oct- Nov- Dec- Jan-
07 07 07 07 07 07 07 07 07 07 07 08
Executive Summary
Leverage
Read Across Implemented. Additional Savings Calculated: None
Knowledge Captured (Lessons Learned) Completed: N/A
Multiple Metric Rolling Top 5

Updated?: N/A

Line 100 High Plunge FACTUAL Project 020808

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Problem Definition Tree

High Plunge - Line 100

LINE: 100 From: 3/1/2007 To: 4/1/2007

Pareto Chart - High Plunge Scrap Cost ($) by P/N

Event Defect Feature Property Problem is a malfunction event

Marry-up Other Plunge force can only be measured at marry-up

Green Y = Plunge Effort (lbs)

Other failure Forensic evidence showed large quantity of foreign

Pareto: majority of FM were weld beads. Foreign material

Foreign Material Source

WOW Location BOB Location

Plunge Force Before & After Tear Down Inspection

Original Plunge Plunge after foreign material removed

Staffing Matrix: Project Leader Marcelo Lavigne

Plunge Effort = Force to collapse / extend shaft

Strategy Selected / Strategy Diagram Developed:

Measurement System Verified: Isoplot passed acceptance criteria: DR = 6.4

Red X Candidate Identified: Weld beads.

Effectiveness of Corrective Actions Verified: Green Y Run Chart:

$20,000 Fixes/solutions put in place

Knowledge Captured (Lessons Learned) Completed: N/A

Multiple Metric Rolling Top 5

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