hass rapid change out process - ieee-astr.org rapid change out... · accelerated stress testing and...
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Accelerated Stress Testing and Reliability Conference
HASS Rapid Change Out Process
Derik Clayton & Julie Stuckey
Honeywell Federal Manufacturing & Technologies, LLC
The Department of Energy’s National Security Campus is operated and managed by Honeywell Federal Manufacturing & Technologies, LLC under contract number DE-NA00002839.
www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida
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Accelerated Stress Testing and Reliability Conference
Overview
www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida 2
Common Solution for all Products
• Significant Increase in HASS Testing Requirements
• Chamber Capacity Constraints
• Floor Space Constraints
• Needed Common Solution for Diverse Products
• Areas of Opportunityo Tester
o Fixturing
o Change-Over
o Mistake Proofing
o Ergonomics
o Storage
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Accelerated Stress Testing and Reliability Conference
Current State
www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida 3
Current Practices Will Not Support Future Demand
• One part currently undergoes HASS testingo Dedicated Chamber and 3 Bay Tester
o 4 products tested at once
o Fixtures “permanently” installed in chamber parts loaded into fixtures
o Multiple electrical connections made in the fixture
o Complex product – extensive test times to allow for electrical coverage during HASS testing
o Significant Floor Space required to support a single product.
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Accelerated Stress Testing and Reliability Conference
Problem Statement
www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida 4
How do we optimize throughput while minimizing capital expenditure and assuring quality?
• 5 distinctly shaped products require testing• What are the common elements we can leverage?• What will change-over look like?• What is the maximum number of products
that can he tested at one time?• Smallest footprint possible with easy
product flow• What do the operators think?
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Accelerated Stress Testing and Reliability Conference
Common Tester for all ProductsCustomized with Adapters
Tester Challenges
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• www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida 5
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Accelerated Stress Testing and Reliability Conference
• Fixtures/product orientation
• Ducting configuration differences
• Cable organization and change out
• Unnecessary related weight on the chamber
• Operator tooling access
• Storage
• Common procedures
Chamber Challenges
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• www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida 6
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Accelerated Stress Testing and Reliability Conference
• Reducing variations and eliminating wasteo Reducing change out time
o Universal designs and setups
o 5S standards
• Concept design development and selectiono Modified Pugh
• Implementation and Controlo Sustain the gain.
Six Sigma – Problem Solving Tools
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• www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida 7
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Accelerated Stress Testing and Reliability Conference
• Develop goals and define weighted factor of importance.
• Analyzed concepts against established goals
• Recognize strengths and weaknesses in each proposed design or concept.
• Converge on a hybrid design to maximize strengths
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Six Sigma – Modified Pugh
• www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida 8
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Accelerated Stress Testing and Reliability Conference
• Minimize the process step variationsoGeneric procedures written as base templates for all products to
be tested
oProduct specific steps highlighted to more easily identify procedure differences
• Assembly outside of chamberoModified current process to assembly as much of the product,
fixture, and cabling as possible outside the chamber
oMistake Proofing
Common Processes / Procedures
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• www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida 9
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Accelerated Stress Testing and Reliability Conference
•Repeatable and consistent UUT placement inside the chamber
o Labeling on the product fixture
o Modify the standoffs
o Color Coding
o Resistor IDs
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Modified Standoffs
Keyed
Rapid Change Over - Fixturing
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Accelerated Stress Testing and Reliability Conference
Rapid Change Over - Ducting
• Redirecting air by means of plenumso Customized plenums for use across
numerous productso Optimizing product placement
• Quick connect pinso Allows for quick removalo Collet on end of ducts
• Universal connection pointso Six Sigma design – standardizeo Unique designed plenums
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• www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida 11
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Accelerated Stress Testing and Reliability Conference
Rapid Change Over - Cabling
• Cable fixturingo Mistake proofing built into the fixture
• Cable tray in chambero Keeps cables organized and out of the wayo Isolated from vibrationo No added weight on the vibration table
• Break out boxo Product specifico Universal Connectors
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• www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida 12
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Accelerated Stress Testing and Reliability Conference
• Design Engineeringo Separate design facility with dedicated chambers for running HALT testing
• Production Facility o Separate production facility with dedicated chambers for running HASS
• Collaborationo Early development design fixturing and cabling input
Collaborating with HALT
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Accelerated Stress Testing and Reliability Conference
• Implementing a “5S” workplace organizational and housekeeping methodology for lean manufacturing processo Sort, set in order, shine, standardize, sustain
• Why is it important?o Space, time, money, energy saving
o Enhances productivity
o Reduces waste
Storage
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Accelerated Stress Testing and Reliability Conference
• Reduced each change over time by 1.2 hrso From current process: 121 total steps, 110 during “change over”
o To current process: 89 total steps, 38 during “change over”
• Design Engineering and Production Engineering collaborationo Reduced duplicated efforts and rework
o Production Engineering leading the fixture design efforts and decisions
• Improved Ergonomics
• Reduced risk of making mistake
• Adaptable to future products
The Impact
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Accelerated Stress Testing and Reliability Conference
•Reducing HASS change-over times allows greater utilization of capital equipment
•Areas to considero Common Test Equipment
o Flexible Fixturing
o Mistake-Proofing
o Ergonomics
o Storage
Summary
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Rapid Change-Over is Key for Increased Production Output
• www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida 16
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Accelerated Stress Testing and Reliability Conference
• References–G. Hobbs, “HALT and HASS: Accelerated Reliability Engineering”:
Westminster, CO: Hobbs Engineering Corporation, 2005–H. McLean, “HALT, HASS & HASA Explained: Accelerated
Reliability Techniques”: Milwaukee, WI; ASQ Quality Press, 2000 –T. Pyzdek and P. Keller, “Six Sigma Handbook: A Complete Guide
for Green Belts, Black Belts, and Managers at All Levels”, New York, NY: McGraw-Hill Education, 2014
–S. Pugh, “Total Design: Integrated Methods for Successful Product Engineering” First Printed 1990. Reprinted 1991.. ed. Wokingham, England ; Reading, Mass.: Addison-Wesley Pub., 1991
–D. Mc Dermott, “Decision Making Confidence: How to use the Pugh Matrix” [http://www.decision-making-confidence.com/pugh-matrix.html]
– Institute of Environmental Sciences and Technology, “IEST-RP-PR003.1 HALT and HASS”: Arlington Heights, IL, September 2012
–M. Imai, “Gemba Kaizen: a Commonsense, Low-Cost Approach to Management”, New York, NY: McGraw-Hill 1997
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