process control for investment casting · nalco water, an ecolab company. 1. ... the process...
TRANSCRIPT
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PROCESS CONTROL for Investment Casting
ICI Regional MeetingMontreal, Canada
June 19, 2019
Presented by: Preston Sanford
Nalco Water, an Ecolab Company
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1. Were you able to find the root cause?
2. Did you follow a process to solve it?
3. How long did it take?
4. Did the problem ever come back?
Who’s ever been given a problem to solve?
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We’ve all seen this:
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◼ Flat Tire
◼ Out of Gas
◼ Car Accident
◼ Pulled Over
◼ Mechanical trouble
◼ Taking a phone call/texting
◼ Spilled food/drinks
◼ Upset Children
WE NEED MORE INFORMATION TO KNOW!
What could the problem be here?
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The 3P’s of Process Control
◼ The Purpose - to learn techniques and skills to
apply in the context of the problem-solving process
◼ The Process – Tools will be introduced and applied
through the simulation of a real-life problems
◼ The Payoff – You’ll understand the problem-solving
process, and how the process control tools are
applied.
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What exactly is a process?
“A unique combination of tools,
materials, methods and people
engaged in producing a measurable
output.”
First Things First…
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Process
Y = f (x)
•Inputs
Sample Process
X Y
•Outputs
The goal of Process
Control is to identify
and reduce sources of
variation
Goal: a Stable
and Measurable
Output
Stable Output
requires a
Stable Input
Stable Input occurs
when you
reduce/eliminate
Variation
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Trust the Process
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What exactly is Process Control
then?
And why is it important?
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Definition:
Activities involved in ensuring a
process is predictable, stable, and
consistently operating at the target
level of performance with only
normal (common cause) variation.Source: Business Dictionary.com
Process Control is
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A Controlled Process ensures:
1. Consistent, high quality products
2. Avoidance of costly mistakes
3. Easy detection if “out of control”
4. A safe working environment
5. Customer confidence
Why is it important?
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To control any process,
we must first
understand the problem
solving method
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Process Control Problem Solving Phases
Define Measure
Analyze Improve Control
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Problem Solving Phases – Define
The DEFINE phase is simply about defining the
problem.
This is done with a well crafted problem
statement.
“If I had an hour to solve a problem, I'd
spend 55 minutes thinking about the
problem and 5 minutes thinking about
solutions.” ― Albert Einstein
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What Makes a Good Problem Statement?
A good problem statement will
1. Define the PROBLEM
2. Include a MEASUREMENT method for the
problem
3. Define the customer REQUIREMENTS
4. Define the current CAPABILITY to produce to
these requirements
5. Define the GOAL
6. Define WHEN it will be completed
7. Determine the WORTH of correcting the
problem
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Process Control Problem Solving Phases
Define Measure
Analyze Improve Control
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Problem Solving Phases – Measure
In the MEASURE phase we are measuring the
problem.
In this phase we need to learn everything we can
about the problem. The problem is the key output
variable (KOV) we are trying to improve.
• Where do you get the data?
• Is the output objectively measurable?
• Is the data used to measure the output reliable?
• Based on the data, what is a realistic goal?
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Problem Solving Phases – Measure
Can you think of a time you made a decision based
on bad data?
What was the outcome?
How could the outcome have been improved if the
data used to make the decision was “better”?
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Process Control Problem Solving Phases
Define Measure
Analyze Improve Control
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Problem Solving Phases – Analyze
In the ANALYZE phase the focus is on identifying all
potential Key Input Variables (KIV).
What is an Input Variable?
Any input to an operation that could vary.
A key input variable has direct or indirect effect on
the Key Output.
There are many input variables but only a few have
an effect on the Output.
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How do we determine all Input Variables?
With the use of:
1. A detailed Process Flow Diagram for the area
of interest
2. A list of hypotheses for the cause of the issue
3. Using a structure brainstorming session, fill
the funnel with potential High Level Causes
4. Narrow down the list of Variables using a
Cause and Effect matrix
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Process Flow Diagram Example
Inject wax
pattern
Inspect
wax
patternGood?
Pattern
coolingYes
NoYields,
defects
Scrap
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Cause and Effect Diagram Example
A Cause and Effect diagram, also known as a
fishbone or Ishikawa diagram, is used to reveal the
reasons behind a problem.
This diagram is used in brainstorming sessions to
help identify all of the likely causes of the problem
(effect).
Effect
Causes (input) Effect (output)
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Process Control Problem Solving Phases
Define Measure
Analyze Improve Control
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Problem Solving Phases – Improve
Now that we have a list of Key Input Variables, we
need to determine which impact our Key Output
Variables.
This is done by:
▪ Conducting screening tests to determine the
relationship of the most promising input
variables to the Key Output▪ Single or Multi-Factor testing
▪ Conduct optimization testing to discover the
ideal settings for each Key Input▪ High and Low testing conditions
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You’ve Solved the Problem!
So now you’re done, right?!?
WRONG!!!!
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Process Control Problem Solving Phases
Define Measure
Analyze Improve Control
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Problem Solving Phases – Control
In the CONTROL phase we establish methods to
sustain the gains.
An effective control system focuses on two aspects:
1. Prevent the problem from occurring.
2. Detect when a problem has occurred.
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Types of CONTROL methods include:
1. Process Documentation
2. Monitoring
3. Reaction Plans
4. Training
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1. Process Documentation
What documents are used to establish
process consistency?
•Generic Instructions
•Part Specific Instructions
•Calibration and Maintenance
•Standard Work
•Checklists
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2. Monitoring
Monitoring systems will detect when
the Key Input Variables are out of
control
•Alarming
•Audits
•Control Charts, Run Charts
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3. Reaction Plans
A reaction plan is a predefined procedure for
reacting to a outcome. It can be simple or
complicated. Examples include:
1. Adjusting slurry viscosity
2. Troubleshooting bubbles in wax patterns
3. Quarantining parts
Reaction plans can be very effective when
included in a control chart or a decision
diagram!
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3. Reaction Plan Example
Viscosity Run Chart
Zahn #5 Viscosity in Seconds; 11.5 to 13 seconds Pounds of
waterAdjust the viscosity to the middle of the range (12.2 seconds)
13.5 17
13.4 16
13.3 15
13.2 14
13.1 13
13 12
12.9 11
12.8 10
12.7 9
12.6 8
12.5 7
12.4
No A
ddit
ion
s
12.3
12.2
12.1
12
11.9
11.8
11.7
11.6
11.5
11.4
11.3
11.2
11.1
11
Place dot in box corresponding to initial viscosity reading. Place an X in the box corresponding to the viscosity reading after adjustment
If the slurry viscosity measures 12.7 seconds
The chart tells them to add 9 pounds of water
Because this reading is within specification, do you think all operators would add water unless we told them to?
Vis
cosi
ty
spec
ific
atio
n
ran
ge
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4. Training
An effective training system must
1. Quickly and effectively train associates in
new tasks or skills
2. Prevent quality and safety issues
3. Provide a path for associate development
4. Provide training status for each associate
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4. Training
The best training methods include the
use of:
•Job Instructions
•Operator Evaluation Forms
•Qualification Matrices
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4. Training – Qualification Matrix
Name
Robot
Help
er
Vacu
um
Dip
Opera
tor
Han
dlin
e
Opera
tor
Robot
Opera
tor
Bill1 2 1 2 1 2 1 2
4 3 4 3 4 3 4 3
Fred1 2 1 2 1 2 1 2
4 3 4 3 4 3 4 3
Jack1 2 1 2 1 2 1 2
4 3 4 3 4 3 4 3
Joe1 2 1 2 1 2 1 2
4 3 4 3 4 3 4 3
Emp
loye
es
Training order
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Summary
The use of process controls help with…
• Reducing scrap & rework
• Improving production predictability
• Developing skills and knowledge of
everyone
• Serving our customers
• Making more money!
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ICI Process Control Course
Goal:
To teach students to apply process control
tools in an investment casting foundry in
order to solve a problem and prevent it from
reoccurring
• Learn how to reduce variability in your foundry
• Hands-on experience applying process control tools
• Identify process areas which cause variation
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“Many times the main difference
between mediocre and world
class manufacturing is effective
and meaningful Process
Control”