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  • 1

    S I X S I G M A

    IAMD C T

    Reduce Dimensional Rejections Related toGrinding Process on

    Precision Aerospace Fasteners

    Six Sigma Project

    Son D Tran, Director of QA,AFS - Industry Operations

  • 2

    S I X S I G M A

    IAMD C T

    DMAIC REVIEW

    DEFINE

    MEASURE

    ANALYZE

    IMPROVE

    CONTROL

    Develop charterMap the processUnderstand the voice of the customer

    Reduce Dimensional Variation - Define

  • 3

    S I X S I G M A

    IAMD C T

    Project Overview :Business CaseInternal rejections of Titanium products cause significant scrap, rework and customerreturns. This level of rejection has affected our Key Performance Indicators (KPI),customer backlogs, and Quality and Delivery Performance ratings to major OEM(Original Equipment Manufacturer). Reduction of Internal rejections will increasecustomer satisfaction and improve our KPI.

    Problem StatementDimensional rejections related to the Grinding process(es) of Titanium Hi-Lok inCells 131, 132 and 133 attributed to about 2% rejections of total pieces completed-to-store the last seven months (Sep 01- Feb 02). This attributed to monthly scraploss, plus significant rejections at subsequent processes (i.e., Thread Roll), andincreased in rework and customer returns costs.

    Goal StatementReduce dimensional rejections related to Grinding process(es) in Cell 131, 132 &133, by 50% from current FPY base-line plus annual reduction in scrap cost of 30%end of August fiscal year 2002..

    Reduce Dimensional Variation - Define

  • 4

    S I X S I G M A

    IAMD C T

    Customer Needs / Requirements

    Key Internal customers for Work Cells 131, 132 & 133 are Thread RollDepartment and Inspection.

    External customers are major OEM. Customers are expecting to receive products (ground parts or finished parts)

    that will meet dimensional specification requirements (or Grind-Defect-Free)every time.

    Operational Definition - KQC (CTQ)

    For the purposes of this project, Grind Defects Dimensional characteristics produce by (or affected by) the

    Grinding process(es) of Titanium Hi-Lok in Cell 131, 132 & 133 that do notmeet specifications. Examples are Grip diameter, Pre-Roll TD,Grip Length,etc.

    Project Charter

    See attached charts

    Reduce Dimensional Variation - Define

  • 5

    S I X S I G M A

    IAMD C T

    ProjectCharterGrindDefectsReduction (Reviewed withSponsor andmanagementteam on 3/15/02)

    Product Impacted Titanium Hi-Lok Product Impacted Sales (03 proj $) TitaniumBlack Belt Son Tran Telephone Number 626-855-8545Champion B. Finkenhagen SBU & Plant COI UnruhStart Date 18-Feb-02 Target Completion Date 15-Aug-02Element Description Team Charter

    1. Process: The production process inwhich opportunity exists.

    Grinding process(es) on Titanium Hi-Lok has caused significant scrap,rework and rejections at subsequent process(es) (i.e., Thread Rolldept would rece ives ground pa rts with la rge va ria tion in Grip dia andTD tha t would cause cha racte ris tics such as Major/pitch dia , anddiffe rentia l to exceed specifica tion limits ).

    2. ProjectDescription:

    Describe the ProjectsPurpose and scope.

    Improve grinding process(es) that would yield 50% reduction indimensional defects on Titanium Hi-lok from current base-line

    3. Objective: What improvement istargeted and what will bethe impact on FPY, COPQand C-P?

    BSL GOAL ENT units

    (First Pass Yield) FPY 95.6 97.8 %

    (Cost of Poor Quality) COPQ 9K+(Scrap)

    99.6% beginning FY03.

    5. Team members: Who are the full-timemembers and any expertconsultants?

    Bruce Finkenhagen Champion, Jeff Railton Coach (BB)Son Tran Project Leader, Hady Elkobaitry CI, Sandy Yaeger SPC,Larry Rainbolt Engineering, Brent Covan Quality Engineer. BobAdame Manufacuring, John Gonzales Process Owner

    6. Project Scope: Which part of the processwill be investigated?

    Grinding process(es) on Titanium Hi-Lok at Work Cell 133

    7. Benefit toExternalCustomers:

    Who are the finalcustomers, what benefit willthey see and what are theirmost critical requirements?

    External OEM customers (i.e., Boeing) and distribution centers willreceive products that meet dimensional specification requirements(less escapes)

    8. Schedule: Give the keymilestones/dates.

    Project Start 18 February, 2002

    M- Measurement M Completion 18 March 2002

    A- Analysis A Completion 30 April 2002

    I- Improvement I Completion 30 June 2002

    C- Control C Completion 30 July 2002

    Note: Schedule appropriateSafety Reviews.

    Safety Reviews

    ProjectCompletion

    08/15/02

  • 6

    S I X S I G M A

    IAMD C T

    Project Summary Purpose

    Reduce escapes thus increase Supplier Performance Rating >99.6%Reduce scrap, rework and customer returns. Increase avenue hence job retention Importance

    Scope

    Measure

    ResourcesBruce Finkenhagen - VP Operations - Team SponsorEd Johnson - Senior VP Quality Assurance - Team SponsorSon Tran - Team LeaderBrent Covan - Quality EngineerLarry Rainbolt - Manufacturing EngineerBob Adame - Grinding Team LeadHady Elkobaitry - Continuous Improvement Manager(BB)Sandy Yaeger - SPC Manager (BB)John Gonzales - Manufacturing Manager

    Grinding Processes of Titanium Hi-Lock at Work Cell 133

    Improve machine capability with no major capital investment expenditure

    Defect = Dimensional characteristics that do not meet specificationsGoal = Reduce 50% dimensional defects at Grinding from current FPY base line

    Improve machine capability by identifying the major process element(s) through datacollection and process analysis, then establish and maintain process parameters tocontrol the process. Complete in (6) month

    Deliverables

    Reduce Dimensional Rejections Related to Grinding Process of Titanium Hi-Lok

  • 7

    S I X S I G M A

    IAMD C T

    OutputsInputs MeasurementSystem

    Router

    MeasurementSystem

    Router

    FIS 2000

    SPCStation

    MPS

    MPS

    Point Finish

    Grind Profile(Rough)

    Grind Profile(Finish)

    Fillet Roll

    Thread Roll

    Drill &Countersink

    MPS

    C

    Heading/Tooling Machine set-up Operator

    Tooling Machine set-up Operator

    Tooling Machine set-up Operator

    Tooling Machine set-up Operator

    Tooling Machine set-up Operator

    Tooling Machine set-up Operator

    Tooling Machine set-up Operator

    Accept/Reject lots Valid Rejection Next OPS

    Accept/Reject lots Valid Rejection Next OPS

    Accept/Reject lots Valid Rejection Next OPS

    Accept/Reject lots Valid Rejection Next OPS

    Accept/Reject lots Valid Rejection Next OPS

    Accept/Reject lots Valid Rejection Next OPS

    Accept/Reject lots Valid Rejection Next OPS

    Broach

    C

    C

    MPS

    C

    MPS

    C

    SIPOC Analysis - Hi-Lok Cell 133

  • 8

    S I X S I G M A

    IAMD C T

    Communication Plan for Black Belt ProjectReduce Dimensional Rejections from Cell 133 Grinding Process of Titanium Hi-Lok

    Son Tran - Project LeaderRole Who

    (Names of people or groups)Main Concerns Communication Notes

    (When and how you will communicate with them)Team Leader

    (BB)Son Tran Time Constraints

    Functional responsibilitiesN/A

    TeamMembers

    Brent Covan QELarry Rainbolt MEBob Adame Grind LeadHady Elkobaitry CISandy Yaeger - SPC

    Time Constraints Functional responsibilities Concurrent projects

    Team meeting 3 times /wk Obtained mgmt commitment 4 hrs /wk

    Sponsor(s) Bruce Finkenhagen VPOPSEd Johnson Sr. VP QA

    Cap Ex Limits Current backlog No OT / Down Time

    Bi-weekly project review Seek concurrence on key items

    Coach(MBB)

    Jeff Railton Process changes Tooling changes

    Obtain concurrence of key issues Weekly status review

    Customer(s) Thread Roll DeptFinal Insp.OEM

    Unaware of processchanges

    Invite to team meeting on Analysisphase.

    Distribution of meeting minutesProcessOwner

    John Gonzales Mfg Mgr Resources Constraints Down Time

    Team meeting 3 times /wk Obtained mgmt commitment 4 hrs /wk

    OtherStakeholders

    Olivier Jarrault - COO Cap Ex Limits Current backlog

    Bi-weekly project review Obtain approvals on key items

    Communication Plan

  • 9

    S I X S I G M A

    IAMD C T

    DMAIC REVIEW

    DEFINE

    MEASURE

    ANALYZE

    IMPROVE

    CONTROL

    Data Collection Data AnalysisProcess Sigma Process Map

    Reduce Dimensional Variation - Measure

  • 10

    S I X S I G M A

    IAMD C T

    Project Summary

    * Annualized OM impact.

    Business Unit Fairchild Fasteners -Industry Operations

    Reduce Dimensional Rejections Related to Grinding Process of Titanium Hi-Lok Project Description

    Goal/Objective

    COI/OEMBenefits

    Financial Benefits $150,000 + approximately

    Sponsors Bruce Finkenhagen & Ed Johnson

    Reduce the number of Dimensional Rejections in the Grinding processes byidentifying the major process element(s) through data collection and process analysis,then establish and maintain process parameters to control the process.

    Receive a Quality part, and on-time delivery.

    Black Belt Son Tran

    Grind-related Dimensional Characteristics that Do Not Meet Specifications. Defect Definition

  • 11

    S I X S I G M A

    IAMD C T

    Leveraging

    Learnings gained - PUSH (Anticipated)BB LocationSon Tran Apply "Lessons Learned" to Other product Family

    Learnings gained - PULL

    Dept. BB / GB Location ProjectProject Status