build up reduction on extrusion process

ConMed Chihuahua Six Sigma Green Belt

Training – 2st.Wave

Chihuahua, MexicoJanuary 2013

Project

Team Members …

• Oscar Macias GB leader• Jose Luis Sanchez• Alfredo Roacho • Gildardo Parra - Champion • Eduardo Rodriguez• Cristina Castillo• Manuel Saucedo• Jorge Marquez• Ruben Vizcarra Black Belt

Scrap Reduction by contamination in tube.at Extruder # 1 & 2

September 2012 - January, 2013

Define

Measure

Measure

Attributes agreement analysis

Resina cruda Interna 1Punto negro 2Resina quemada 3Resina cruda externa 4Pieza bien 5

21

100.0

97.5

95.0

92.5

90.0

87.5

85.0

Appraiser

Perc

ent

95.0% CIPercent

21

100.0

97.5

95.0

92.5

90.0

87.5

85.0

Appraiser

Perc

ent

95.0% CIPercent

Date of study: Reported by: Name of product: Misc:

Assessment Agreement

Within Appraisers Appraiser vs Standard

Measure

Gage R&R Study - ANOVA Method Only with bag

Part-to-PartReprodRepeatGage R&R

100

50

0

Perce

nt

% Contribution% Study Var

1.0

0.5

0.0

Parts

Samp

le Ra

nge

_R=0.45

UCL=1.158

LCL=0

1 2

24

16

8

Parts

Samp

le Me

an

__X=12.1UCL=12.56LCL=11.64

1 2

2019181716151413121110987654321

24

16

8

Parts

21

24

16

8

Operators

24

16

8

Parts

Avera

ge 12

Operators

Gage name: Date of study:

Reported by: Tolerance: Misc:

Components of Variation

R Chart by Operators

Xbar Chart by Operators

Appraisers by Parts

Appraisers by Operators

Parts * Operators Interaction

Gage R&R (ANOVA) only with bag

18

12

6

18

12

6

18

12

6

1

Operators

C6

2 3 4 5 6 7

Mean

8

Mean

9 10 11 12 13 14

15 16 17 18 19 20

Mean

12

Operators



Panel variable: Parts

Gage Run Chart of C6 by Parts, Operators

Measure

Gage R&R Study - ANOVA Method With car

Part-to-PartReprodRepeatGage R&R

100

50

0

Perc

ent

% Contribution% Study Var

2

1

0

Parts

Sam

ple R

ange

_R=0.575

UCL=1.480

LCL=0

1 2

24

16

8

Parts

Sam

ple M

ean

__X=12.25UCL=12.84LCL=11.66

1 2

2019181716151413121110987654321

24

16

8

Parts

21

24

16

8

Operators

24

16

8

Parts

Aver

age 1

2

Operators



Components of Variation

R Chart by Operators

Xbar Chart by Operators

C6 by Parts

C6 by Operators

Parts * Operators Interaction

Gage R&R (ANOVA) with car

40

32

24

40

32

24

40

32

24

1

Operators

con c

arrit

o

2 3 4 5 6 7

Mean

8

Mean

9 10 11 12 13 14

15 16 17 18 19 20

Mean

12

Operators



Panel variable: Parts

Gage Run Chart of con carrito by Parts, Operators

Measure

Analyze

Affinity Diagram

extrusorasende build upGeneracion

Medio ambiente

Medicion

Metodo

Material

Maquinaria

Mano de obra

Turnos

Falta de entrenamiento

Arreglo de temperaturas inadecuadas

Presion inadecuada

Melt inadecuado

Herramientas de limpieza no disponibles

Plato rompedor dañado

Pin, dado y cabezal dañado

Tornillo dañado

herramientas no adecuadoMaterial para limpieza de

particulas negrasMaterial contaminado por

Diferentes tamañosn de Pellets

no uniformePellets deformados/ Formacion

Limpieza de plato rompedor

Acumulamiento de material

Limpieza de dado, pin y cavezal

Rango de temperaturas

Limpieza de extrusora

Gaylord descubierto

Descomprimir resina con remo

Gage para medir cucaracha

cajasGeneracion de particulas de las

Cause-and-Effect Diagram

Analyze

6’M why? hypothesis

Cause demonstration of hypothesis

Material

Pellets improperly formed/ pellets

with different size

Inadequate cleaning materials

Absence of inventory control / lack of material

contaminated by black particles

Material burned in the development

of pellets

Analyze

t

W

Analyze

Extruder 1Analyze

Extruder 1

Analyze

Extruder 2

Analyze

Analyze

California TennesseeAnalyze

Lack of material

Analyze

• During the preview measurement not founded black particles in 250 gaylords

Analyze

6’M why? hypothesis

Cause Demonstration of hypothesis

Personnel

Poor training

Different knowledge

between operators

ShiftsDifferent technique

of operators by shift

Analyze

Extruder 1

Extruder 2

Cabezal

Cabezal

Cabezal

Cabezal

Analyze

Extruder 1

Extruder 2

Analyze

Extruder 1

Extruder 2

Cabezal

Cabezal

Analyze

Extruder 1Analyze

Extruder 2Analyze

6’M Why?Hypothesis


Method

Cleaning of Screen plate

Material accumulation

Absenteeism/ unbalanced

Temperature range

Uncover Gaylord

Unsuitable top

Assembly of die in head

Having a bad assembly of die will cause leaks

resulting resin burned in the die

Analyze

Analyze

Extruder 1

Extruder 2

Analyze

Extruder 1Analyze

Extruder 2Analyze

Analyze

Nominal Parameters 1/4 ID 125 fpm Line Speed

290

295

300

305

310

315

320

325

Barrel # 1 Barrel # 2 Barrel # 3 Barrel # 4 Barrel # 5 Barrel # 6 Barrel # 7 Clamp Dado # 1 Dado # 2

Recommended parameters apply to an of extruder 7-barrels

0

50

100

150

200

250

300

350

Barrel #1

Barrel #2

Barrel #3

Barrel #4

Barrel #5

Barrel #6

Barrel #7

Clamp Dado #1

Dado #2

Tem

pera

ture

F

←Extruder 1

Extruder 2→

Analyze

Extruder 1Extruder 1

Analyze

Extruder 2Extruder 2

Analyze

Analyze


CauseDemostration of hypothesis

Measurement Not gage for

build up measurement

N/A

Analyze



Environment Generation of carton particles

Uncontrolled

environment

Analyze

Analyze



Machine

Screen plate, Die, Head, Pin and Screw

Damage

The surface of all tooling through which flows the resin must be completely

smooth without scratches or damage if there is damage in the tooling, the resin will

accumulate in cracks or rough surfaces and burned in that area.

Tools Cleaning not available

If you do not have the right tools for cleaning machinery and equipment not cleaned

properly You might still leave in the tooling, burned material

Melt inappropriate

Recommended melt for the PVC Flexible resin

Pressure Inappropriate

Analyze

Extruder 1

Extruder 1Analyze

Extruder 1

Analyze

Extruder 1Cabezal

Cabezal

Analyze

Extruder 2

Extruder 2Analyze

Extruder 2

Analyze

Extruder 2Cabezal

Cabezal

Analyze

Analyze

Extruder 1

Analyze

Extruder 2Analyze

Analyze

extruder 1

Analyze

extruder 2

Analyze

Screen pack Arrey Ex. 1

←Time

Size→

Analyze

←Melt

←Pressure

Analyze

Screen pack Arrey Ex. 2

←Time

Size→

Analyze

←Melt

←Pressure

Analyze

IMPROVE

• Material Improvements.

Improve

CauseImprove

Pellets improperly formed/ pellets

with different size

Inadequate cleaning materials

1. Apex Teknor provide the material until of Tennessee they fix the process in California, the date must be no longer than one month.

2. Is added to CIP 1003791 the size and shape of pellet uniform even with photographs.

1. We implemented a Kanban system for chemical inventory and is documented in the EWI-068-M

Improve

CauseImprove

Cleaning of Screen plate

Temperature range

Uncover Gaylord

1. We standardized the method of cleaning the plate breaking and documented in the EWI-068-M

2. The area was fitted with the necessary tools to properly clean your plate and inspect the work

Method Improvements.

1. Validation of the extruder # 2 in temperature ramp-

Improve

Assembly of die in head

Improve

We standardized the method of assembly of die and the procedure is documented in

EWI-068-M

Improve

Improve

CauseImprove

Machine Improvements.

Screen plate, Die, Head, Pin and Screw

Damage

Melt inappropriate

Pressure Inappropriate

1. Validation of the extruder # 2 in temperature ramp-

1. We implemented the arrangement # 2 mesh to increase the pressures over 1000psi and is documented in the EWI-068-M set up of extruders.

Identify each tooling, die and pin and will be creates a

verification and replacement procedure.

This Procedure is documented in the EWI-068-M

Improve

Improve

White Room Improvements.

Implementar recorrido semanal 15 minutos con Supervisor e Ingenieros para revision de area y filtros

Yosselyn Eslava / Oscar Macias / Luis Carrera / Jose Luis Sanchez / Miguel Baez

Continuo a partir del 27-

Sep-12

27 Sep: Se realiza primer recorrido. Ver anexo C.4 Oct: Se realiza segundo recorrido. Ver anexo.

Auditoria de areas de tecnicos de STB (equipo, gavetas)

Carolina Carmona 27-Sep-12

27 Sep: Completado el 24 de sep. Ver anexo D.4 Oct: Se lleva semanalmente. Se anexaran auditorias a reporte, se encuentran los tecnicos en espera de que llegue el carro SMED.

Implementar en sistema TMS Mantenimientos programados para limpieza del exterior del equipo de extrusion

Roel Ramirez Done 27 Sep

Proponer junta con Nico / Rogelio / Roel para disposicion de equipo

Oscar Macias / Yosselyn

Eslava / Luis Carrera

27-Sep-12

27 Sep: Nico trae esa actividad. Gerardo esta investigando que se puede ir y que no, en espera de respuesta (Claudia) 12 oct

Improve

• Validating Improvements.

Improve

JAN FEB MAR APRIL MAY JUNE JULY AUGUST SEP OCT NOV DEC

EXTRUD

E

0 UNCLASSIF

1 BAD MATERIAL

2OPERATOR ERROR

3ENGINEERING ERROR

4 QA SAMPLE

5 TEST MATERIAL

6SCRAP DUE TO MACHINE SET UP

$ 14,393.65

$ 14,432.12

$ 12,204.77

$ 8,529.78

$ 9,786.12

$ 5,973.11

$ 9,655.07

$ 11,896.28

$ 6,646.28

$ 4,848.35

$ 5,108.39

$ 3,045.88

7

OBSOLETE VIA ECN &/OR MARKTNG

8MACHINE MALFUNCTION

9 RGA MATERIAL

TOTAL EXTRUDE

$ 14,393.

65

$ 14,432.1

2

$ 12,204.7

7 $

8,529.78 $

9,786.12 $

5,994.84 $

9,655.07

$ 11,896.2

8 $

8,003.65 $

6,678.85 $

5,108.39 $

3,045.88

Cost Material

$ 383,683.53

$ 553,397.

09

$ 428,925.

39

$ 419,695.

35

$ 529,390.

69

$ 401,317.

95

$ 400,704.

96

$ 495,986.

88

$ 370,875.

97

$ 477,810.

72

$ 363,633.

21

$ 273,533.

50

% Scrap 3.75% 2.61% 2.85% 2.03% 1.85% 1.49% 2.41% 2.40% 1.79% 1.01% 1.40% 1.11%

Sem

ana

# 36

Sem

ana

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ana

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ana

# 39

Sem

ana

# 40

Sem

ana

# 41

Sem

ana

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Sem

ana

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Sem

ana

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Sem

ana

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Sem

ana

# 46

Sem

ana

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Sem

ana

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Sem

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Sem

ana

# 50

Sem

ana

# 51

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

Scrap por Semana de Extrusion

Libr

as

Meta: 890 Lbs

Improve

Economic Benefits of ProjectBaseline:

Historical data (Scrap average first 9 months): $ 2,380.60 dlls per month. 0.53% of Scrap by contamination$ 28,567 dlls anual

Achieved 0.079% of Scrap by contamination

85 % of improvement This improvement represents a potential saving of $24,282 dlls from the $28,567 historical data.

• PFMEA Update

Improve

– Mitigation of potential causes that generates scrap.

• Daily scrap monitoring.Control

Daily meeting to review scrap

Control

• Plan Control Update

Control

• Follow up Activities

ActividadStatus Fecha de terminacion Responsible

Actualizacion del CIP de la resina 1003791En Proceso

28 de Enero del 2013 Cristina Castillo

Implementacion de Kanban de Quimicos y Elaborar el procedimiento En Proceso 24 Enero Del 2013 Oscar Macias

Validacion de Extrusora 2 Temperaturas Tipo Rampa 3 corridas de OQ y 3 Corridas de PQ En Proceso 14 De Febrero del 2013 Oscar Macias

Implementar todas las tapas de los gaylors En Proceso 28 de Enero del 2013 Oscar Macias

Documentar la mejora del ajuste de dado con torque establecido a 5lbf En Proceso 31 de Enero del 2013 Oscar Macias

Mandar a Identificar los dados, pines y platos rompedores y elaborar procedimiento de reemplazo

En Proceso 7 Febrero del 2013 Oscar Macias

Documentar el arreglo de mallas para elevar la presion de extrusion a mas de 1000 Psi En Proceso 31 de Enero del 2013 Oscar Macias

Questions?

build up reduction on extrusion process

Documents