Download - sealing open project

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.



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

Download - sealing open project

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