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Scrap Reduction

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by

Jarrod Dixon

on 25 April 2013

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Transcript of Scrap Reduction

Six Sigma Define- Gap varying from 1.5 mm at supplier to 2.5 mm at VW
Specification - No gap allowed Measure Ultimate goal can be ZERO Defect, which is the company goal for maximum profit. If there is “0” defect our manufacturing cost will be low which in turn maximizes profit.
Ideal situation will be what we can ideally achieve with the ultimate goal of zero defects. May be an overall scrap rate of 2%
Current situation is where you currently are standing. Scrap rate is 5% which is below ideal situation. The reason for your scrap rate being at 5% are the problems present. Analyze Ishikawa Diagram Control Project Charter Scrap Reduction of WKW Bright Trim at VW Chattanooga Six Sigma Black Belt Project
By: Jarrod Dixon Project Objectives Reduction of Scrap Customer Satisfaction Zero Defect Rate!! Key Stakeholder's Project Start Date: CW 12/13
Project End Date Goal: CW21/13 Lee Whyman- Quality Mgr. Jarrod Dixon- Supplier Quality Engineer- Production Michael Hayes- Measurement Tech. Jeffery Bate- Supplier Quality Engineer Process Importance Visually Offensive to Customer Success of New MFG. Facility Cost Of Quality Scrap Rework Sorting Audit Complaints Supplier Ratings Future Business Goals 0 Defect Rate at VW Higher Profit Margins for supplier Define the issue at hand Problem Analysis Epoxy resin was used to build up the tongue to simulate the hole location shift and create more interference to the cap.

After the trials showed an improved fit condition to the cap, the mold tools were modified to move the hole location 2mm inboard to create the increased interference. Improvement Step Before Change After Change C Pillar upper extrusion Additional rib at C Pillar joint Ribs extended 1 MM Problem Analysis -WIP rack better supports the C pillar to reduce stress on upper C pillar mould.

-WIP rack keeps the C pillar moulded detail straight whilst waiting for the coating process, and provides correct storage after coating process.

-WIP parts are fully supported correctly throughout the moulding process. Ensuring the part is not allowed to bend at the C pillar moulding. Improve Improvement Step -WIP rack better supports the C pillar to reduce stress on upper C pillar mould.

- WIP rack keeps the C pillar moulded detail straight whilst waiting for the coating process, and provides correct storage after coating process. Increased Support = Better part condition in final assembly Improvement Tracking Step-Down Diagram Quality Card/Efficiency Checks Capability Study III for gap at c pillar results: Other Control Methods
-Six cycle checks to ensure proper handling of in process parts

-Weekly PM checks of in process and final assembly racks

-Daily measurements of extrusion runs for all parts of window guide The key to success is to never stop learning. The key to failure is to think you know it all. Results -Gap at c pillar resolved
-Removal of Third party containment on site
-Scrap Rate to 0% from 5% for this issue
-Audit points eliminated
-Profit margins increased
-Decrease of rework at VW
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