sealing open project
TRANSCRIPT
Reduction in rejection due to sealing open by 50%.
Asia EIT Convention 2015
Project Name : To reduce sealing open rejection 1.3 % to 0.03 %
Date ( Revision by) :Prepared By : KHUSHAL R. TALHANApproved By: AMOL KHANDAGALE
BUSINESS CASE : OPPORTUNITY STATEMENT (HIGH LEVEL PROBLEM STATEMENT )
Vishay componenets India pvt ltd, it is a world largest manufacture of semiconductor and passive components.
To improve the yield , rejection percentage ,and cost of poor quality.
.
DEFECT DEFINATION : metal is not fully covered entire area by plastic film.otherwise plastic film is opening during next operation.
GOAL STATEMENT : PROJECT SCOPEReduce the rejection of sealing open and thread open of Film capacitor. Process start point : AT WINDING STAGE .
Expected Saving / Benefits COST OF SAVING 1,60,16000
Process End Point : FINAL CONTROL INSPECTION STAGE
Project Plan : Team :
Task / PhaseStart Date End Date
Actual Date Name Role
Commitment
Define 07-Jan-14 22-Jan-14 22-Jan-14 KHUSHAL TALHAN DATA COLLECTION 95% Measure 20-Feb-14 22-Feb-14 24-Feb-14 TANAJI PHALKE ACTION 99% Analyse 10-Mar-14 28-Mar-14 30-Apr-14 RANJIT MALGAR MONITORING 99%
Improve12-Apr-14 03-Apr-14 15-Apr-14 GANESH SATAV
HORIZONTAL DEPLOYMENT. 99%
Control 06-May-14 22-May-14 30-May-14 AMAR JANGAM MONITORING 99%
TEAM / PROJECT CHARTER
winding flattening
interleaving
Metal spray
waxing
deburring
detapping Healing and
sorting
Final control
Process Flow Diagram of Capacitor
At this stage
sealing open is detect
ed
Defect generation
stage
Initial detection of
defect
SIX SIGMA DMAIC PHASEIdentify problem DEFINE
Practical Problem
MEASURE
Root cause analysis
ANALYZE
Problem solution
IMPROVE
Problem control CONTROL
Total Front End Yield in year 2013 – 92.1%
Breakage of 7.9% rejection Mechanical defects : 4.12 % Electrical defects :3.78 %The process engineering dept has taken project of
Electrical Defects
Focused on mechanical defects
1.
33
Why theme is selected ?
0.00
20.00
40.00
60.00
80.00
100.00
Rej
ect.
%
Break up of mechanical rejects in % 1.3%
Cost of poor Quality
$
Issue No. of pieces Scrapped in 2014
Sealing open 3.6 mln
Cost of poor quality = 3600000*5 RS = 1800000 RS
$ 494K
1. TURNOVER: RS 1993.4 MLN
2. PBT :RS 176.3 MLN
To improve film cap yield 85%
Dept action plan : Reduction in rejection of sealing open issue by
50%
Linkage to quality Policy
Project leaderA.T.Khandagale
(Maint. Engineer)
T.M.Phalke(Maint. Engineer)
K.R.Talhan(Quality .Engin
eer)
G.B.Satav(Jr.Maint. Engineer)
Malgar R.S.(Prod. Operator)
Assembly follow-up
Defect mode analysis
Standardization
Data collectionEquipment
ImprovementResult check Solution action
Data collection Assembly follow-up Result check Horizontal
deployment
Data collectionRoutine CheckProduction trialsResult check
Team Organization
No. of Meetings Held : 10
Meeting Calendar
Date 7.01.15 22.01.15 20.02.15 10.03.15 28.03.15 12.04.15 3.05.15 6.06.15 25.06.15 21.07.15Meeting at 3.00 p.m.Team Attendance
100% 100% 80% 100% 100% 80% 100% 100% 100% 100%
In that meeting we got root cause of sealing open problem.
1. Data collection2. Brainstorming3. Pareto analysis4. Ishikawa diagram5. Why-Why analysis6. Variable search( DOE)
Tools used to solve problem
Activity planning (Gantt) Chart
Activities Planned Responsibility Wk No. W1402 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44
Data collection of sealing open issue KHUSHAL
Planned
Actual
Analysis of available data Team
Planned
Actual
Action Plan as per analysis T.M.Phalke
Planned
Actual
Execution of actions Satav/KulkarniPlanned
Actual
results confirmation on machines. KHUSHAL
Planned
Actual
Horizontal Deployments on all machines groups,
Satav/Kulkarni.Planned
Actual
Sealing Open
Define problem – Sealing open
Good
Bad
Bad
Flap open
Thread open
Rejection 30%
Rejection 70%
Measure problem – Sealing openSealing problem faced on winding
stageFollowing are the different winding machines and sealing open percentage as per following
Rejection of sealing issue is 1.33%
Machine Name
Present sealing rejection
Present sealing Profile
Stella Romeo
0.97 50% Land Sealing
Stella ERO 0.01 Cover film + 50% Land
VHW 0.05 Cover film + 50% Land
Ariane 0.2 50% Land Sealing
Cosmos 0.15 50% Land Sealing
AVM 0.04 50% Land Sealing
BC 2000 0.01 Cover film + 50% Land
From above study it is finalized that sealing open rejection on stella Romeo machine
Data collection – Sealing open for stella romeo m/cs
Date Machine No. Foil Micron
Sealing temp
Sealing Profile Problem Observed Action taken
18.02.2014 Stella fl. 6e-5 12 310 Square Threads open Clean the pencil.
20.02.2014 Stella fl. 6e-9 6.2 290 Square Flap open Sealing not parallel so adjust grub screw.
22.02.2014 Stella fl. 6e-4 6.2 280 Square Threads open Sealing not parallel so adjust grub screw.
25.02.2014 Stella6e-1 6.2 280 Plain Flap open Clean the pencil and adjust the grub.
27.02.2014 Stella fl. 6e-2 12 320 Square Threads open Sealing not parallel so adjust grub screw.
02.03.2014 Stella fl. 6e-6 6.2 280 Square Threads open Reduce sealing temperature
04.03.2014 Stella fl. 6e-10 12 310 Square Threads open Sealing not parallel so adjust grub screw
05.03.2014 Stella fl. 6e-4 6.2 290 Square Flap open Sealing not parallel so adjust grub screw.
08.03.2014 Stella fl. 6e-5 12 310 Square Threads open Reduce sealing temperature
10.03.2014 Stella fl. 6e-11 12 320 Square Threads open Sealing not parallel so adjust grub screw.
11.03.2014 Stella fl. 6e-12 12 310 Square Threads open Clean the pencil and adjust the grub
13.03.2014 Stella 6e-5 6.2 280 Plain Flap open Sealing not parallel so adjust grub screw.
15.03.2014 Stella fl. 6e-9 6.2 280 Square Threads open Clean the pencil and adjust the grub
16.03.2014 Stella 6e-8 12 310 Plain Flap open Sealing not parallel so adjust grub screw.
17.03.2014 Stella fl. 6e-4 6.2 280 Square Threads open Clean the pencil and adjust the grub
19.03.2014 Stella fl. 6e-2 6.2 290 Square Threads open Clean the pencil and adjust the grub
21.03.2014 Stella fl. 6e-12 6.2 280 Square Threads open Reduce sealing temperature
Remark : Various trial conducted to find various causes of sealing open fault, no conclusion from trials.
Further analysis of sealing open
Sr.No. Types of sealing open Action taken to solve problem
1 Flap open Sealing not parallel so adjust grub screw.
2 Threads open
Clean sealing pencil
Set the temperature
Team decided to work initially on seal , flap open problem.
Why why Analysis of sealing flap open
Sealing pencil not parallel. Why ?
Grub Screw for parallel adjustment found loose. Why ?
After 1 week Compression spring pressure was getting reduced at working temp. up to 350 °C . Why?
Present Compression spring material was loosing properties at temp 350 °C.
Team Investigated and decided to replace material of Grub screw and compression spring which can sustain up to 600°C temperature.
Root Cause of
the Problem
Analysis of Comp. spring Material
Type of spring material Trial
Life of spring(Spring
Length -14mm) Not ok <10mm
Remark
Hard spring steel W1511Not ok after one week used
Not Suitable
Stainless steel spring steel W1512
Not ok after two week used
Not Suitable
EN12070 W1512Not ok after two week used
Not Suitable
Inconel X750Ni Cr 15 Fe 7 Ti Al W1514
OK even after 4 Week used(length remain 14mm)
Suitable
Team decided to use material Inconel X750
Result after spring material change
After changing compression spring – Sealing flap open rejection is eliminated but sealing threads open rejection is still 0.95% hence team decided to study on threads open rejection
Horizontal deployment and standardization
Machines/Group No. of Machines Available
No .of Machines Completed Status
Stella Winding 46 46 Completed in week 1526
Standardization
Description12 NC
Old New
Compression Spring 8203 110 32550 8203 110 32551
Sealing pencil compression spring replacement frequency defined one year in Preventive Maintenance Check sheet.
Sealing pencil spring drawing, stock no., changed in Spare list..
Fishbone diagram – Sealing thread Open
Sealing thread Open
Untrained operator
Sealing pencil not parallel
MAN
METHOD
MACHINE
Wrong parameter setting
WINDING
WINDING
Profile of Sealing pencil is not ok
MATERIAL
FILM No Method for inspection
Improper sealing due to high speed
Sealing open due to low Temp
Sealing open due to wrong setting of temp
Sealing Pressure not proper
Film MKT Film MKP
Film thickness
Solenoid stroke not standard
Compression spring not ok
Serration of sealing pencil worn out
Play in Pencil Guide way
Grub screw loose
3
1
2
Sealing thread open – Ranking methodVariables Verification Data Influence
1) Sealing open due to wrong setting of temp
Checked temperature and found range 280-320 in work instruction. Yes
2)Serration of sealing pencil worn out
Verified and corrected during preventive maintenance No
3) Improper sealing due to high speed
Sealing speed is verified and found as per instructions No
4)Sealing pencil profile design is not suitable.
Product observed under microscope ,spikes observed at non contact area of pencil.
Yes
5)Film thickness Difference in rejection quantity according to film thickness Yes
6)Play in Pencil Guide way Verified and corrected during preventive maintenance
No
7) Solenoid stroke not standard Solenoid stroke length defined and Verified during preventive maintenance No
SR.NO. FACTOR DESCRIPTION
LOW HIGH
1 Sealing temperature 280 320
2 Foil Thickness 6.2 12
3 Sealing profile(Land %) 50% 100%
From data analysis three parameters affects on sealing thread open ,Hence team decided variable search of these three parameters.
LAND
DEPTH
ROOT
SEALING PROFILE
Full Factorial Design
Factors: 3 Base Design: 3, 8Runs: 16 Replicates: 2
PARETO ANALYSIS DOE
Remark: From above graph sealing land is significant parameter.
MAIN EFFECT AND INTERACTION PLOT
REMARK : SEALING LAND IS SIGNIFICANT ,NO INTERACTION IS SIGNIFICANT
DESIGN OPTIMISER SETTING
REMARK : SEALING LAND SETTING 100% AND SEALING TEMP IS CHANGED ACCORDING TO FILM THIKNESS.
Before
SEALING PENCIL DRAWING After
Land 50% Land 70%
Horizontal deployment and Standardization
Description12 NC
Old New
Sealing Tip--Stella 7604 004 27691 7604 004 27692
Sealing Tip Left--Cosmos 7604 004 27671 7604 004 27672
Sealing Tip Right--Cosmos 7604 004 27681 7604 004 27682
Sealing Tip--Araine No 7615 511 00200
This change is regularized thru Change proposal no. : CP-L13084
Machines/GroupNo. of
Machines Available
No .of Machines
CompletedStatus
Stella winding 46 46 Completed 1539
AVM Machines 3 3 Completed 1540
3e-11e VHW Group 16 16 Completed 1544
Ariane Group 8 8 Completed 1541
Cosmos Group 16 16 Completed1543
1 20
0.20.40.60.8
11.21.4 1.33
0.340000000000
001
sealing open
sealing open
Target Achievement
50% 70
%
orignal
target achieved
RESULTS OF REJECTION
1.28%
0.72%
REMARK : AVERAGE REJECTION % FOR SEAL OPEN IS REDUCED FROM 1.28% TO 0.35%
Cost of saving =Rs 1,60,16,000
Cost of Saving =0.99% reduction X 4 Mln X52 weeks X 5Rs
Results - saving
$ 267K
Thank you