Paint Plant. Data Driven Quality Performance Improvement .September 2014 – January 2016

QUALITY

Plan- GLOBAL 8D. Structured Approach using 8 Disciplines.D1. Form the Team. Cross Functional selected from Paint and Maintenance departments1.Facilitator P.Cunningham.2.Champions S.Fitter. Yogi Krawetz. P.Segui

DIRT 8D Team . Pre Clean, Base Coat, Lacquer, Polish, Maintenance personnel and Paint Team Leader

Plan- GLOBAL 8D. Structured Approach using 8 Disciplines.

D2. Describing the Problem.

1.Variable Right First Time Performance on painted Bodies viewed at Gateway 3 Buy Off. During September 2014 Averaging 70 % Failures which required Paint repairs.

2. Highest RFT Failure Mode on bodies was for dirt. Dirt count from 300 to 700 pieces on all panels around the body.

3.Variable ability to support track requirement which is between 8-10 bodies per day. Track stoppages waiting for Bodies to be available after Paint Combi repairs. Body bank for track was empty. The Body bank should have a minimum of 2 and a Maximum of 10 ready to go on Pre Mount. 4. Various opinions of where Dirt originates from.

Plan – Implement Gateway 3 RFT Measuring from Week 33 2014

2014 to 2015 Week 33 to Week 52 RFT Comparisons

wk 45 2014.Unable to carry out cleaning procedures during October shutdown

Plan – Analyse RFT Failures. 2014 to 2015 Comparisons

Count

Perc

ent

Paint Plant. Gateway 3 Defects

Count 3 1Percent 34.319.717.914.9 5.7 3.6 1.8

1150.9 0.9 0.3

Cum % 34.354.071.986.992.596.1

66

97.998.899.7100.0

60 50 19 12 6 3

350300250200150100500

100806040200

Paint RFT Failures weeks 33 to 52 2014

Count

Perc

ent

Paint Plant. Gateway 3 Defects

Count 2 2 1 1 0Percent 41 17 12 7

396 5 3 2 2 2 1 1 0

Cum %

16

41 58 69 77 83 88 92 94 96 98

11

99 100100

7 6 5 3 2

10080

604020

0

100806040200

Paint RFT Failures weeks 33 to 52 2015

Wk 33 to 52 2014 – 374 RFT Fails to CombiAverage 21 Bodies per week

requiring Combi repairs

Wk 33 to 52 2015 – 95 RFT Fails to CombiAverage 5 Bodies per week

requiring Combi repairs

Do- GLOBAL 8D. Structured Approach using 8 Disciplines.

D3. Containment. Protecting the Customer. Our Customers are Gateway 3 Buy Off and Pre Mount on the Track.

These are the Containment Actions that were implemented.

1.BIW – Green Room. A more thorough vacuum of bodies for iron filings from BIW rework.

2.Post Scuff Booth blowing off of dust. Tak off Bodies inside and out. Water Wash and Tak off bodies before going into Pre Clean Room.

3.Pre Clean. Clean with White Spirit ,tak off and heat with infa red lamp.4.Base Coat .Final Tak, Base and Dry.5.Lacquer booth . Dry , Tak and Lacquer.

Do- GLOBAL 8D Structured Approach using 8 DiciplinesD4. Root Cause Analysis. Team Based Input.Cause and Effects Dirt in Painted Parts. 17 High Ranked Potential Causes

Do.GLOBAL 8D.Structured Approach using 8 Diciplines.

D4. Root Cause Analysis.

Areas of focus resulting from 17 Ranked High Potential Causes.

1.The condition of the Paint Facility through wear and tear particularly through the aggressive nature of Lacquer.

2.Little or no Booth Cleaning Programme. No regular frequencies.

3.A review of Critical to Quality Maintenance. Inclusive of Base and Lacquer fans that incur high build ups of paint material that lead to fans being out of balance. This increases vibration of the booths which leads to increases of dirt onto the vehicles from the ceilings of Base Coat and Lacquer Booths.

4.Frequency and level of cleaning and re sealing of oven floor. This is not structured or regular.

5. Lack of early warning “Trigger Points “ for Dirt levels that could be increasing at Critical stages of Processing.

Do.GLOBAL 8D.Structured Approach using 8 Diciplines.D5.Permanent Corrective Actions.1. Facility Deep Clean. Develop a working standard for elements that

were failing or broken. The initial 30% was carried out in September 2014. The remaining 70% carried out at Shutdowns in October, Christmas and Easter 2015. Lessons learnt put into Maintenance PPM’s schedules.

2. Development and Implementation of Pre Clean, Base Coat and Lacquer booth Daily and Weekly Cleaning program.

3. Oven Maintenance . Weekly and Fortnightly vacuum and Floor Resealing

4. Fortnightly Base Coat and Lacquer Fans cleaning. Continuous rotation. Of fan cleaning.

5. Oven Floor repairs and re sealing around floor filters where floor breaking away and increasing dirt levels.

6. Closed Door Policy introduced for all booth areas from BIW Combi through paint plant to end of Oven. Doors are kept closed.

7. Better organisation of overalls and consumables for Spraying.8. Clean up of Blowers and improved rotation for cleaning when fouled

with Base Coat and Lacquer paint.

Check.GLOBAL 8D.Structured Approach using 8 Diciplines.

D6. Validation. “ Being Proactive as opposed to Reactive”

1.Pre Start Checks on Critical to Quality Parameters. For Pre Clean Room , Base Coat and Lacquer Booths.

2. Statistical Process Control chart ( SPC ) monitoring Twice Daily After Lacquer v Post Oven Dirt counts on Bodies. Monitoring Individual and Range . Identifying Trends.

3. Statistical Process Control chart ( SPC ) Chart monitoring Body to Body dirt counts on Bodies at Gateway 3 Buy Off. Monitoring Average and Range. Identifying Trends.

4. Use of Thermal Imaging camera inside oven weekly, to monitor temperature levels and also to identify heat leaks.( cracks in oven floor.)

Check.GLOBAL 8D.Structured Approach using 8 Diciplines.

D6. Validation – Trigger Points.Pre Start Checks. 07.00 Daily.Pre Clean, Base Coat and Lacquer booths.1.Walk and Audit .2.Adhering to established Care Point Standards

SPC.At Lacquer v Post Oven. Twice Daily. 2 Pts rising = STOP and validate Pre Clean to Oven

SPC Body to Body Gateway 3. 4 Points rising = STOP and Validate Pre Clean to Oven

Act..GLOBAL 8D.Structured Approach using 8 Diciplines.D7. Prevention. Using Data to make informed decision making. “Being Proactive rather than Reactive”

1.Pre Start Checks on Critical to Quality Parameters. Stop / Fix Approach. Pre Clean Room, Base Coat and Lacquer booths.

2.Statistical Process Control . (SPC) Dirt After Lacquer v Post Oven. After Lacquer 50 pieces + 10 pieces. After Oven 150 pieces + 20 Max / 2 Points rising is a Stop / Validate Processes and Facility from Pre Clean ,Base Coat, Lacquer and Oven.

3.Statistical Process Control. ( SPC ) Dirt Body to Body 150 pieces + 50 pieces / 4 Points rising or an extreme High Count is a Stop / Validate Processes from Pre Clean, Base Coat ,Lacquer and Oven.

“Right Routines for the Right Reasons at the Right Time- Every Time!!!”

“We do not knowingly – Accept, create or pass on Defects.”

A Picture Says a Thousand Words. Well Done the Team !!!!!!D8.Congratulate the Team.