Six Sigma Green Belt Project

1
Six Sigma Green Belt Project 1250-XX
Covers Reduction of Raw Material Cost by
Utilizing Regrind
Green Belt Candidate, Tempe 07/13/07
2
-Define-

• The purpose of this project is to determine
  if the blending of 25 regrind into the GE Ultem
  1000 will significantly change the Key
  dimensional and visual characteristics of the
  1250-XX covers. We will focus on the 1250-05 for
  data collection as this is our highest volume
  part for this Customer in this category.
• If successful, this will eliminate the
  scrapping of the GE Ultem 1000 runners plus
  reduce the amount of virgin material necessary to
  complete the orders.

3
-Process Map- Material Purchasing
4
-Measure-MSA Instructions
Instructions -Using the Zeiss CMM program
1250-05 Six Sigma Post Only, run sample parts in
order. Samples are identified 1-10. Setup (See
pictures below) Place 1.500 spacer in H2.(2x
.750) Place .750 spacer in H7. Position 1250-05
sample upside down on spacer with gate at 45
degree angle to the bottom left. Snug down with
second .750 spacer. Follow instructions
contained in program for Base Alignment criteria.
Gate at 45 Degrees
5
-Measure- Measurement System Analysis
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Measurement System Analysis contd.
Less than 10 of the tolerance is taken up by
measurement error indicating that the Zeiss CMM
program is an acceptable way to accurately
measure the Key characteristics. Gage RR
Contribution Source VarComp
(of VarComp)
Total Gage RR 0.0000000 0.99
Repeatability 0.0000000 0.99
Reproducibility 0.0000000 0.00
Part-To-Part 0.0000002 99.01
Total Variation 0.0000002 100.00
StdDev Study Var
Study Var Tolerance Source (SD)
(5.15SD) (SV)
(SV/Toler)
Total Gage RR
0.0000483 0.0002488 9.95
2.49 Repeatability 0.0000483
0.0002488 9.95 2.49
Reproducibility 0.0000000 0.0000000
0.00 0.00 Part-To-Part
0.0004832 0.0024885 99.50
24.88 Total Variation 0.0004856
0.0025009 100.00 25.01
Number of Distinct Categories 14
7
-Measure-Key Dimension Capability using 100
Virgin Material
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-Measure-Key Dimension Capability using 100
Virgin Material
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-Measure-Key Dimension Capability using 100
Virgin Material
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-Measure-Key Dimension Capability using 25
Regrind
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-Measure-Key Dimension Capability using 25
Regrind
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-Measure-Key Dimension Capability using 25
Regrind
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-Measure-Key Dimension Capability using 100
Regrind
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-Measure-Key Dimension Capability using 100
Regrind
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-Measure-Key Dimension Capability using 100
Regrind
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-Analyze-
A t-Test is being used to show that there is no
significant difference in the means between the
100 Virgin material and the Virgin material with
25 Regrind. With the P-value being greater than
Alpha (.05), we fail to reject the Null
Hypothesis (Ho) on all 3 Key Characteristics.
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-Analyze-Contd.
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-Analyze-Contd.
Samples were run with 100 Regrind to see what
effect it had on the Key Characteristics.
t-Tests were used to show if a significant
difference in the means had been caused by the
change. With P-values remaining greater than
Alpha (.05), we fail to reject the Null
Hypothesis (Ho) on all 3 characteristics proving
there is no significant difference in dimensional
readings when 100 Regrind is used.
19
-Analyze-Contd.
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-Improve-

• The Improvement phase will implement the usage of
  25 Regrind added to the virgin material during
  normal production runs. The Work Order template
  will be updated in the Shared Directory to
  accurately reflect the percentage of regrind
  allowed. Correct usage of material will be
  verified during the QA Sign-In and initialed. The
  Bill of Materials will also be amended.

21
-Control-

• The Customer defined Key Characteristics will
  be monitored after the introduction of regrind
  during the molding operation using a variety of
  tools. Sign-In and In-Process dimensional
  inspection criteria are controlled and
  communicated via the Mold Data Book. The QA
  Sign-In at the start of the run will include the
  Customers current A-079 inspection form available
  from their Customer Website. In-Process data
  will be entered into real-time SPC Charts in the
  Quality Control Lab and will be monitored by
  Quality Inspectors. Any unusual variation in the
  SPC Charts will be investigated. Out of
  specification product will be quarantined and
  properly labeled with an Non Conforming Material
  Report per the ISO standard and dispositioned
  accordingly.

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-Control-
Copy of Mold Data Book Page-
In-process Dimensional Inspection criteria.
Copy of Mold Data Book Page- Sign-In Criteria
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-Control-
Sample Customer A-079 Inspection Form
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-Control-
Copy of Blank NCMR
Sample SPC Chart
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-Cost Savings-
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-Cost Savings-
Extrapolated to include all the 1250-XX Covers
that do not specify 100 Virgin Only including
-02, -05, -08, -10, -11, -12
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-Conclusion-

• After measuring samples run with 25 Regrind/75
  Virgin and samples run with 100 Regrind, it has
  been concluded that there were no significant
  differences or changes in the Customers Key
  Dimensions. Cpk levels ranged between 2.64 and
  9.94 indicating all values are well above the
  2.00 Cpk of a stable 6-sigma process. Taking
  into account normal process variation and the
  likeliness that the process may drift, it can be
  assumed that the values will remain within the
  Customers specifications.
• Tensile strength testing will need to be done by
  the Customer to verify overall strength and
  integrity has not been compromised due to this
  change.
• With an annual savings of 5,687.34 for the -05
  configuration, the potential cost savings if
  applied to all of the 1250-XX part numbers would
  be 13,655.25 annually.