School of Engineering + Technology

• Define• Scope

• Measure• Value Stream Map

• Defect Pareto Graph

• Analyze• Cause and Effect map

• Improve• LWM Detection for Part Cleanliness

• Control• Recommended Actions

Laser Differential Welding Process Control

Requirements

Problem Statement Results

Team & Acknowledgements

DMAIC Approach

• Laser weld is considered a Special Process under the AS9100 specification

• The products produced using this process have tight requirements around laser parameters, part cleanliness, seam location, penetration depth, and porosity.

• These parameters and metrics need to be closely monitored to prevent non-conformances.

• Define• Problem Statement• Requirements• Scope

• Measure• Explore process map• Defect Pareto Graph

• Analyze• Cause and Effect map• VSM• PFMEA

• Improve• Detection

• Control• Recommended Actions

Sponsor• Ben Thomas and Mark PlessMentor• Wes StoneMechanical Engineering• Thomas Farrell• Jonah BurnettEngineering Technology• Joshua Allison• Trey Chandler• AJ Summers• Bryce Clapsaddle• Davis Burnham

Summary• DMAIC approach used to select critical X (Part

Cleanliness) to improve• Software configuration refined to detect part

cleanliness• Test of configuration successfully detected dirty parts

Task Description Value Status

1 Develop process parameters for defect settings

264 Front Differential Series

Complete

2 100% quality check with a 50% reduction in defects

1% defect rate over 1000 parts

Complete

• Lowering the 2% scrap rate.

• Determining what causes welds to fail

• Correct the faults through experimentation and calculations.

What's In? What's Out?• Making edits to the

software.• Operating the laser.

Final Design

Thomas Farrel AJ Summers Joshua Allison

Click to add text

Jonah Burnett Trey Chandler Davis Burnham Bryce Clapsaddle

Backlight Reflection Process Capability(PpK 0.71)

Ultraviolet Process Capability (Ppk 0.62) Infrared Process Capability (Ppk 0.90)

Laser Weld Monitoring overlay of 3 Test Parts