duffy pad project

Quality Control Pillar Board / Sterling Heights Assembly Plant



D uff y Pad Leak

Duffy Pad Leak

• SUBJECT: Duffy Pad Leak

• PROJECT LEADER: Ray Peterson




D uff y Pad Leak

Duffy Pad Leak

Sketch of Defect

Flash on Inner Rubber Seal



Sketch of Phenomenon

Water Leak

Excess FlashGaps Formed from Excess

Flash

Body of Vehicle



Data StratificationDate VIN Problem Shift found on Water Test Shift problem occurred at on line6-Feb 204585 Unseated Leak 1 N/A15-Feb 215413 Unseated Leak 1 N/A25-Feb 221174 Seated Leak 1 N/A28-Feb 214748 Unseated Leak 2 N/A1-Mar 218550 Seated Leak 1 N/A

15-Mar 241553 Seated Leak 1 N/A19-Mar 242618 Unseated Leak 1 N/A20-Mar 238371 Seated Leak 2 121-Mar 237130 Unseated Leak 2 15-Apr 251626 Seated Leak 1 2

11-Apr 251126 Seated Leak 1 211-Apr 261269 Seated Leak 1 112-Apr 237694 Seated Leak 1 112-Apr 257161 Seated Leak 1 117-Apr 261609 Unseated Leak 1 118-Apr 249868 Unseated Leak 2 120-Apr 274760 Unseated Leak 2 121-Apr 259582 Unseated Leak 1 123-Apr 263538 Seated Leak 1 225-Apr 262774 Seated Leak 1 226-Apr 260977 Seated Leak 1 126-Apr 260993 Unseated Leak 1 228-Apr 253956 Unseated Leak 1 228-Apr 262839 Unseated Leak 2 128-Apr 263713 Unseated Leak 1 228-Apr 267418 Unseated Leak 2 128-Apr 269070 Unseated Leak 1 230-Apr 270864 Unseated Leak 1 11-May 252326 Unseated Leak 2 21-May 253677 Seated Leak 1 11-May 261951 Unseated Leak 2 11-May 262417 Unseated Leak 1 11-May 266749 Seated Leak 1 11-May 271004 Seated Leak 1 21-May 277688 Unseated Leak 2 12-May 267335 Unseated Leak 1 13-May 265359 Seated Leak 1 23-May 269107 Unseated Leak 1 23-May 275927 Unseated Leak 1 24-May 277617 Unseated Leak 1 14-May 283373 Unseated Leak 2 27-May 262201 Unseated Leak 2 17-May 276018 Unseated Leak 1 2

10-May 278720 Seated Leak 2 210-May 281449 Seated Leak 1 210-May 284545 Seated Leak 2 210-May 289660 Seated Leak 1 110-May 289722 Seated Leak 2 210-May 293499 Seated Leak 2 1

11-May 275130 Seated Leak 1 111-May 277287 Seated Leak 2 211-May 279529 Seated Leak 2 211-May 281480 Unseated Leak 1 211-May 293446 Seated Leak 1 112-May 279582 Seated Leak 1 112-May 289903 Seated Leak 2 114-May 282515 Unseated Leak 1 114-May 290053 Seated Leak 2 114-May 290892 Seated Leak 2 115-May 284691 Seated Leak 2 115-May 297116 Seated Leak 2 116-May 273110 Seated Leak 2 116-May 293721 Seated Leak 2 216-May 297710 Seated Leak 2 117-May 278894 Seated Leak 2 117-May 287157 Unseated Leak 1 217-May 293761 Seated Leak 1 118-May 293161 Seated Leak 2 119-May 292517 Seated Leak 2 119-May 292729 Seated Leak 2 119-May 297858 Seated Leak 2 219-May 304397 Seated Leak 2 122-May 287393 Seated Leak 2 123-May 293359 Seated Leak 1 224-May 279945 Seated Leak 2 225-May 279921 Seated Leak 1 225-May 284467 Unseated Leak 1 130-May 263455 Seated Leak 1 130-May 284284 Seated Leak 1 131-May 291624 Seated Leak 1 131-May 292691 Seated Leak 1 11-Jun 284861 Seated Leak 1 11-Jun 289076 Seated Leak 1 22-Jun 300447 Seated Leak 2 24-Jun 268538 Seated Leak 1 24-Jun 320724 Seated Leak 1 24-Jun 330254 Seated Leak 2 15-Jun 284773 Seated Leak 1 15-Jun 284892 Seated Leak 1 15-Jun 291247 Seated Leak 2 25-Jun 307234 Seated Leak 1 26-Jun 279885 Unseated Leak 1 26-Jun 311731 Seated Leak 1 16-Jun 323731 Seated Leak 1 17-Jun 309835 Seated Leak 1 27-Jun 325649 Seated Leak 1 28-Jun 295732 Seated Leak 1 18-Jun 320870 Seated Leak 2 28-Jun 325649 Seated Leak 1 28-Jun 330364 Seated Leak 1 114-Jun 313802 Seated Leak 2 114-Jun 330998 Seated Leak 1 2



Start of Project



Nominalized Data of Defective Duffy Pads

JSC41 JSD41 JS270.80

0.85

0.90

0.95

1.00

1.05

1.10

Normalized Data of Defective Duffy Pads

C/10

00 O

ccur

renc

es

1.05

0.91

1.08



Seated Duffy Pad Leaks by Shift (3/18-6/18)

Total number of Duffy Pad Leaks by Shift (3/18-6/18)

5739

53%47%

Seated Duffy Pad Leaks by Shift(3/18-6/18)

1st shift 2nd shift

62%

38%

Unseated Duffy Pad Leaks by Shift (3/18-6/18)

1st Shift 2nd Shift

1st Shift 2nd Shift0

10

20

30

40

50

60

Total number of Duffy Pad Leaks by Shift (3/18-6/18)

Num

ber o

f Occ

uran

ces

3950



February March April May June0

5

10

15

20

25

30

35

40

Seated Leaks vs. Unseated Leaks (3/18-6/18)

Seated LeakUnseated Leak

Month

Num

ber o

f Occ

urre

nces




D uff y Pad Leak

Duffy Pad Leak

``

LineMachineDate 6/5/2012

Initial Phenomenon:

What

When

Where

Who

Which

How

Revised Phenomenon

* How is the state of the equipment changed from the optimal? How many times does the problem occur?

Optimally there should be no water leak on the duffy pad. The rate of apperance of the phenomena has steadly increased since February 2012.

Water leak on duffy pad through BIW opening located under IP. The phenomena is discovered during water testing. The phenomena occurred during continuous running. The phenomena has been spotted on the JSC41, JSD41, and the J27. The phenomenon effects the quality team, SQA, chassis UL, chassis TL and chassis assembly. The condition is random in nature and affects both shifts. Roughly fifty-six percent of total defects take place on the first shift. Optimally there should be no water leak on the duffy pad. The rate of apperance of the phenomena has steadly increased since February 2012.

* Where did you see the phenomena? Where on the equipment or material did you see the phenomena?

The phenomena has been spotted on the JSC41, JSD41, and the J27.

* Who does it effect? Everyone? Or is it less of a problem for some individuals or teams? (If so, what info can they offer?) Is it skill related?

The phenomenon effects the quality team, SQA, chassis UL, chassis TL and chassis assembly.

* Which trend or pattern does the phenomena have? E.g. Is the phenomena more frequent on Monday mornings? After a change-over? Or is it random in nature? Which direction does the phenomena happen in? (Note: Not many phenomena are truly random!)

The condition is random in nature and affects both shifts. Roughly fifty-six percent of total defects take place on the first shift.

5W,1H Analysis Sheet

Duffy pads are experiencing a water leak

* What does the phenomena look like? What product, machine, material was being used? What size?

Water leak on duffy pad through BIW opening located under IP.

* When did the phenomena occur? When in the sequence of operation; startup, continuous running, intermittent problem, shutdown, changeover?

The phenomena is discovered during water testing. The phenomena occurred during continuous running.




D uff y Pad Leak

Duffy Pad Leak

Revised 4M

Duffy Pad

Operator following SWI

Inner Component BIW Hole not to Spec

Clips

Rivets Operator Using Wrong Tool

Inner seal Paint Sealant covers BIW hole

Operator Trained

Non-robust Design

SWI Correct

Clear and Understandable

Provides Detail

Improper method of handling material

Seated Duffy Pads are Leaking. See 5W1H for more

detail.

Material Man

Machine Method

OK

OK

NOK

OK

OK

OK

OK

OK

1



4 M Investigation Sheet

D uff y Pad Leak

Duffy Pad Leak

Description Activity Data Who Target Status

MATERIAL

Is the inside edge of the body where the duffy pad sits flush?

Checked 50 vehicles/day for two weeks looking for inconsistancies on the inside edge

No signs of jagged edges found after checking a sample size of 500 vehicles

R. Peterson June 1st OK

Is the outside edge of the body where the duffy pad sits flush?

Checked 50 vehicles/day for two weeks looking for inconsistancies on the outside edge

No signs of jagged edges found after checking a sample size of 500 vehicles

R. Peterson June 1st OK

Are the clips loose on the duffy pad?Compared defective duffy pads against ones which were shown to be acceptable

Clips were shown to be resilient regardless if defective or not

R. Peterson June 5th OK

Are the clips damaged on the duffy pad?

Compared defective duffy pads against ones which were shown to be acceptable

Clips were shown to have similar dimensions regardless if defective or not


Are the duffy pads out of position after install?

Checked 50 vehicles for unseated duffy pads Duffy pads are correctly seated R. Peterson June 6th OK

Are the duffy pads a non-robust design?

Checked duffy pads after install for any signs of weakness

Slight pressure easily unseats duffy pad regardless if defective or not. However, this issue is not causing the leak in the duffy pads


Has the design of the inner component of the duffy pad been compromised?

Examined 50 fresh stock along with 10 failed duffy pads

Fresh stock duffy pads were shown to be similar to ones which were compromised


Are the rivits found on the duffy pads defective in any way?

Checked defectve duffy pads along with fresh stock

Rivets on both defective and acceptable duffy pads were shown to be structurally intact


Are the duffy pads that are shipped from the supplier free of defects?

Compared defective duffy pads against ones which were shown to be acceptable

Seal on defective duffy pads differs from those which are acceptable. Defect is approx. 2mm thick, 8mm long, and 10mm left of the longest clip

R. Peterson June 7th NOK

MANAre operators following SWI for duffy pad install?

Observe operator's installing duffy pads on 20 vehicles for consistency.

Operator performed install per SWI R. Peterson. May 29th OK

Are operators using the wrong tool to perform install?

Observe operator's installing duffy pads on 20 vehicles for consistency.

Operator performed install per SWI R. Peterson. May 29th OK

METHODIs SWI clear and understandable? Review duffy pad install SWI SWI is clear to understand and is written correctly R. Peterson May 30th OKDoes the SWI provide detail on the job?

Review duffy pad install SWI SWI provides in-depth detail on procedure R. Peterson May 30th OK

MACHINEN/A

DETAILED ACTIVITIES ON 4M-ANALYSIS

1



5-WHY

1A

1B

1C

1

Effect Potential Causes Corrective Action

Duffy Pad Water Leak 1-WHY 2-WHY 3-WHY 4-WHY 5-WHY Description WHO WHEN

Duffy pad is not fully seated

against vehicle's body

Excess flash on inner seal of Duffy pad

Inner seal is defective from

supplier

Lifter located at supplier is

damagedPIC

PIC containment of excess flash on inner sealant of duffy pad

R. Peterson, E. Lantto,

6/10/2012

OPL

OPL created to make operators aware of

excess flash located on inner seal. OPL implemented by TL

R. Peterson, G. Marquardt

6/12/2012

SQA

Worked with SQA to achieve a clean point on all duffy pad stock

incoming

R. Peterson, A. Hadorn, B. Bush,

A. Del Real

6/22/2012




D uff y Pad Leak

Duffy Pad Leak

"QC" Pillar - Kaizen J ournal of Activities

???? SK Duff y Pad Leak

# Activity Who Target Status Note

1 Complete Data Collection R. Peterson, J . Nava 6/ 18/ 12

2 Complete 5W1H and 4M R. Peterson 6/ 06/ 12

3 Complete 5-why R. Peterson 6/ 12/ 12

4 Review SWI R. Peterson 6/ 07/ 12

5Contacted supplier about excess fl esh located

on inner seal of duff y padE. Lantto, B. Bush, A.

Hadorn6/ 08/ 12

7Add OPL at Chassis install f or excess fl ash on

duff y padR. Peterson 6/ 12/ 12

8 Clean point achieved by supplierE. Lantto, B. Bush,

A. Hadorn 6/ 22/ 12

Clean point has been labeled as such since 6/7/12 by US

Farathane. However as of 6/18/12 clean point has not

been achieved.



Sketch of Solution

Flash on Inner Rubber Seal

No Flash

Before SolutionAfter Solution



Long Clip: Defect located 10mm left of edge

Snapshot of Defect



Target Zero

Defects

0

1

2

3

4

5

Series1; 0

Duffy Pad Leaks Found Since Start of Project (5/25-6/18)

Num

ber o

f Occ

uran

ces

1

1A

OPL Created

Start of Project

PIC Sort

1B



d

WCM009-0

Pupil

Trainer

Date of Training

WCM2012-0612

HOW

Station 1221

6/12/2012

WHYBefore install check inner seal of duffy pad to make sure that no excess flash is present. The flash is located 10mm to the left of the long clip

If the duffy pad has flash on the

inner seal, it will not seat properly.

WHAT: Duffy Pad Install (Decking Cell) Model: JS

Improvement Problem Awareness

Col H20 Completed by: R. Peterson Doc #

ONE POINT LESSON (OPL)

Basic Knowledge

SHAP Dept: Chassis (9170) Zone #1 Team # 5

X

1B




D uff y Pad Leak

Duffy Pad Leak

5 Questions for Zero Defects# 1 3 5 PHASE 0 PHASE 1 PHASE 2 PHASE 3 PHASE 4

1Are the material quality characteristics clear?

A list of characteristics exists The check method exists It's easy to check 1 5

2Exist the incoming material control standard?

There is no standard, but some occasional checks exist

Standard of control exists (incoming material inspection )

Effective and effi cient control (error/mistake proofing,etc.)

1 3

3The supplier capability is sufficient

Cpk is too low, and there are many problems with the supplier

1<Cp<1.33, and there are sporadic problems

Cpk>1.33, and there are no problems

1 3

4Which stage of QC incoming material it's guarantied

The part is in Stages 1-4 of the 8 Stages of Incoming Material Control

The part is in Stages 5-7 of the 8 Stages of Incoming Material Control

The part is in Stage 8 of the 8 Stages of Incoming Material Control

1 1

5Is it easy to restore a correct material characteristic?

No, the incoming material must be scrapped

Standard countermeasures are applied to compensate (process adjustment, etc.)

A robust process exists and can compensate for material anomalies

3 3

TOTAL 28% 60% 0% 0% 0%

QUESTIONANSWER SCORE



Benefit includes annualized repair/re-process cost avoidance, and over-manning elimination


Initial Benefit/Cost AnalysisCost includes team root cause analysis $1,283.28

$9,269.64

B/C = 7.22

D uff y Pad Leak

Duffy Pad Leak

Repair 18/month=>216/year Root Cause Analysis Hours Peterson 30Hours Repair/Year 216 Ken (Water Test) 9Hourly Cost Repair $37.96 Heavy 9

$8,199.36 48

Cost of Replacement Part $4.96 Hourly Rate Intern $20.00Replacement Parts/yr $1,070.28 Hourly Rate for Repair $37.96

Total Manpower Cost $1,283.28Total Benefit $9,269.64

Total Cost $1,283.28B/C Ratio 7.22

Initial Benefit / Cost Analysis

duffy pad project

Career

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