final presentation (jesse columbus)
DESCRIPTION
Final project for my internship.TRANSCRIPT
Summer Internship 8/12/2010
Jesse Columbus
Agenda
Projects
• Production Floor Layout
• Curing Oven Standardization
Main Project
• 8 Fiber MPO Improvement
Project: Production floor Layout
Supported fiber production floor plan re-layout.
Improved equipment ergonomics.
Analyzed floor safety audit and conducted a follow up action plan.
Project: Curing Oven Standardization
• Ovens were rebuilt to new rev. of Tooling
• Profiled for correct temperature and ramp time.
• Verified (bi)monthly, profiled semi annually Actual Temp
Oven Set Temp
Main Project: 8 Fiber MPO improvement
Goal: Improve 8 fiber MPO First Pass Yield (FPY) on polishing without negatively impacting CWS inspection at Endface geometry or IL/RL testing
Identify potential root causes
Methodology
DMAIC process
Define: Fish Bone Diagram
Measure: P-Chart on MPO Production Line
Analyze: F-test, T-test, ANOVA, Correlation study
Improve: New Polisher, Lean Replenishment
Control: Continued SPC charting, Visual Floor Signal
Define/ Measure
Fish Bone DiagramIdentified potential root causes
P-chartNumber of conformingMeasured difference in shifts, operators, and polishing equipment
Analysis / Investigation
Hypothesis – repeating step 4 will increase FPY yield and decrease scratches
Defects were decreased Endface geometry was improved The right histogram shows no difference in the mean. ( Type 2 error)
2
543210-1-2
9
8
7
6
5
4
3
2
1
0
543210-1-2
New
Total Defects
Frequency
OldMean 1.2StDev 1.240N 20
New
Mean 1.35StDev 1.424N 20
Old
Histogram of Total DefectsNormal
Panel variable: Process
1.21.00.80.60.40.2
3.0
2.5
2.0
1.5
1.0
0.5
0.0
FPY
Densi
ty
0.8722 0.1399 120.5333 0.1497 12
Mean StDev N
NewOriginal
Process
Histogram of FPYNormal
Improve (six sigma)
New Domallie Polisher
~35*% increase in FPY
~57% reduction in Variation
Cost savings of $24,000 annually 1.00.80.60.40.20.0
2.0
1.5
1.0
0.5
0.0
FPY
De
nsi
ty
0.7303 0.1896 650.5342 0.2694 92
Mean StDev N
NewOld
Polisher
Histogram of FPYNormal
58% average FPY 76% average FPY
FPY %
Improve (lean)
Demand 500 cables per week
Producing 250 cables per week
Value Stream Map
Water Spider pull replenishment. (50 extra cables per week, $500k annually )
Utilized a worker on the MPO line to maximize throughput at the bottleneck produced by the polishing station.
Minimize non-value added activities.
Control
Kurt SPC-Continued SPC charting, Electronically capture data from the MPO polishing station and record the data into p-chart and spreadsheet.
Will send out of control notification
Signal lights for production floor.
Green = operational
Yellow = need a fiber lead to verify work
Red = engineer assistance needed