© 2002 six sigma academy0 adhesive project example

1© 2002 Six Sigma Academy

Adhesive Project Example


Problem Statement

The amount of adhesive consumed in the assembly operation is higher than specified by engineering, resulting in significantly higher production expenses, which impact profitability of the product.

Target:

Identify the causes of excessive adhesive consumption and reduce the usage of adhesive in the assembly line operation by 400%.

Critical To Quality - CTQApplying the specified amount of adhesive is essential to bond strength.Applying excessive adhesive causes costs to exceed targets.

Benefits Achieved$500,000 savings in material costs for adhesive.


1st Qtr Usage Projected Usage For the Year

Brought in house 14,983 Gal.$174,738

56,479 Gal.$658,689

Usage Per Projected Specification

3,542 Gal.$41,305

13,353 Gal.$155,731

Adhesive Volume/Cost Total Plant

MetricsAdhesive usage and cost


Purging process Purging process --

--Leaking during Leaking during applicationapplication

-Limit switch set up (too high causesLimit switch set up (too high causes excessive adhesive remaining in drums)excessive adhesive remaining in drums)

Over use of Over use of adhesiveadhesiveduring during assemblyassemblyprocessesprocesses

Cause-Effect DiagramCause-Effect Diagram

MachinesMachines

MethodsMethods

ManpowerManpower MeasuresMeasures

- - Drum’s change over processDrum’s change over process

Nozzles Height Nozzles Height --vs. Panel nestvs. Panel nest -- Needed trainingNeeded training

on spec’s.on spec’s.

Pressure set upPressure set up --

-- In- ProcessIn- ProcessMeasurement Measurement systemsystem

- - Nozzles timingNozzles timing

5© 2002 Six Sigma Academy D-M-A-I-C

Current dimensions data: Base line

Date/Spot 257-1 257-2 257-3 257-4 257-5 257-6 352-1 352-2 352-3 352-4 352-5 352-6 381-1 381-2 381-3 381-4 381-5 381-65/21, 12:30 37 42 38 34 41 38 36 33 33 32 33 36 32 35 38 37 35 375/25, 1:16 35 35 31 31 31 32 41 43 36 45 42 40 40 39 41 40 40 425/29, 10:10 32 34 28 27 34 35 41 43 37 47 42 41 41 40 41 39 39 425/30, 3:10 33 35 33 32 34 27 40 38 35 46 36 42 41 42 42 43 41 425/31, 3:00 39 37.5 33.4 31.6 35.1 33.5 42 41 37 48 38 43 45 44 44 44 43 436/01, 5:00 35 38 34 35 37 36 40 36 33 42 36 41 38 36 39 38 36 39

Diameter (mm)


50454035302520

USLLSL

Process Capability Analysis for Diameter

PPM Total

PPM > USL

PPM < LSL

PPM Total

PPM > USL

PPM < LSL

Cpm

Ppk

Z.LSL

Z.USL

Z.Bench

StDev (Overall)

Sample N

Mean

LSL

Target

USL

993932.96

993605.73

327.23

981481.48

981481.48

0.00

*

-0.83

3.41

-2.49

-2.51

4.35552

108

37.8435

23.0000

*

27.0000

Expected PerformanceObserved Performance

Overall Capability

Process Data

Current Process not capable- Negative Sigma Level


DOE - DOE - Optimize Pressure & Time SettingsOptimize Pressure & Time Settings for the dispensing nozzlesfor the dispensing nozzles

"USAGE OPTIMIZATION OF ADHESIVE"TWO LEVEL - TWO FACTORS EXPERIMENT

LINE: 257 / 352 / 381 SHIFT: 2 / 3 DATE: / / Time: ___:___

LEVELS DEFINITION:LEVEL / FACTOR PRESSURE TIMING

HILOW

EXPERIMENT:

RUNS PRESSURE(psi)

TIMING(seconds)

SPOTS DIAMETER(millimeters)

#1 /#2 /#3 /#4 /#5 /#61 HI HI / / / / /2 HI HI / / / / /3 HI HI / / / / /4 HI HI / / / / /1 HI LOW / / / / /2 HI LOW / / / / /3 HI LOW / / / / /4 HI LOW / / / / /1 LOW HI / / / / /2 LOW HI / / / / /3 LOW HI / / / / /4 LOW HI / / / / /1 LOW LOW / / / / /2 LOW LOW / / / / /3 LOW LOW / / / / /4 LOW LOW / / / / /

OBSERVATIONS:______________________________________________________________________________________________________________________________________________________________________________________________________________________

Material: Adhesive (from same drum). Temperature: N/AViscosity: Constant Humidity: Constant

Top of panel

#1 Spots #6


Regression Analysis: Diameter versus Pressure, Time

The regression equation isDiameter = - 39.0 + 0.740 Pressure + 1.61 Time

Predictor Coef SE Coef T PConstant -38.985 8.038 -4.85 0.000Pressure 0.73956 0.09967 7.42 0.000Time 1.6121 0.2100 7.68 0.000

S = 1.596 R-Sq = 94.0% R-Sq(adj) = 93.5%

Time Pressure

25

29

33

37

41

Dia

met

er

Main Effects Plot - Data Means for Diameter

Results Main Effects Plot Regression Model

Results used to optimize settings for nozzles


27 mm27 mmUPPER SPEC..UPPER SPEC..

25 mm25 mmTARGETTARGET

23 mm23 mmLOWER LOWER

SPEC.SPEC.

WRONGWRONGTOO BIGTOO BIG

WATCH FOR THIS DEFECT

WRONGWRONGTOO SMALLTOO SMALL

Visual Aid


BEFOREBEFORE CHANGING ADHESIVE CHANGING ADHESIVE DRUMS CHECK FOR:DRUMS CHECK FOR:

1. The drum to be removed from the line is empty. 2. The piston is all the way down to the bottom of the drum.

3. Air pressure closed for drum to be changed4. T-valve closed for the drum to be changed.5. T-valve open for the remaining drum.

AFTERAFTER CHANGING ADHESIVE DRUMS CHANGING ADHESIVE DRUMSCHECK FOR:CHECK FOR:

1. T-valve is open for both drums.2. Air lines open for both drums; if not, if not, one drum will pump Adhesive to the other.one drum will pump Adhesive to the other.

T-valve

To avoid Adhesive spillage…To avoid Adhesive spillage…

LOSSLOSS

$11.7/gallon$11.7/gallon

There is 25% of adhesive remainingin this drum

Piston is herePiston is at bottom

When plate is here

Visual AidsVisual Aids


Material: PlexiglassMaterial: Plexiglass

23mm23mm 27mm27mm

1000mm1000mm

Measurement tool for Adhesive spotsMeasurement tool for Adhesive spotsPrototype IIPrototype II

Gage type: Go / no goGage type: Go / no go

Higher specification limitHigher specification limit Lower specification limitLower specification limit

60mm60mm

Measurement SystemMeasurement System


11stst Qtr Cost Improved Process Cost Difference Yearly Savings Qtr Cost Improved Process Cost Difference Yearly Savings

$ 0.58/panel $ 0.58/panel $0.24 /panel $0.34/panel $0.24 /panel $0.34/panel $503,000$503,000

Project Results

Actions:Actions:Material handling ChangesMaterial handling ChangesOptimized Application SettingsOptimized Application Settings

Process Capability for Diameter Improved Ppk= 3.1

© 2002 six sigma academy0 adhesive project example

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