waste reduction uponor corporation calen papke mntap advisor: jane paulson uponor supervisor: scott...
TRANSCRIPT
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Waste ReductionUponor Corporation
Calen Papke
MnTAP Advisor: Jane PaulsonUponor Supervisor: Scott Bates
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Company Overview (OO-Pa-Nor)
• Plastic Piping and Component Manufacturer– Plumbing– Radiant Heating– Fire Sprinkler Systems
• PEX-a Extrusion– Polyethylene crosslink– “Engel Method”
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Reasons for MnTAP assistance
• Decrease Product Contamination
• Establish Baseline
• Facilitate project to increase production yield– Research– Plan– Recommend– Implement
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Motivations For Change
• Continuous Improvement Oriented Culture
• “Wildly Important Goals” (WIGs)– 15% reduction in weighed scrap– 15% increase in production yield
• Increase revenues
• Decrease waste-streams
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Approach
• Improve product yield, decrease process waste• DMAIC methodology
– Determine Root Cause– Develop Improvements to reduce, eliminate
• Establish Baselines• Next Steps
Define Measure Analyze Improve Control
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Approach
• Improve product yield, decrease process waste• DMAIC methodology
– Determine Root Cause– Develop Improvements to reduce, eliminate
• Establish Baselines• Next Steps
Define Measure Analyze Improve Control
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Define // Measure
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Baselines // Benchmarks
• Expose and quantify unknown scrap streams– Maintenance scrap– Mixing scrap– Improperly reported scrap
• Convert into consistent figures– Weight– Cost
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Determine Focus of Project
• “Black Contamination” - BC
• “Foreign Contamination - FC
• “Proprietary Additive Contamination” – PAC
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Determine Focus of Project
• “Black Contamination” - BC
• “Foreign Contamination - FC
• “Proprietary Additive Contamination” – PAC
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Define “Black Contamination”
• Black specks or streaks on / in pipe
• Different ‘types’– Major: burnt resin– Minor: tool coating,
component residue
• Doesn’t meet customer standards
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Analyze
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Maintenance Work Orders (WOs)
• 91% of WOs on BC involve work on moving parts
• Info from maintenance scrap tracking pilot (06/12-06/28)
• ‘Band-Aids’ recurring problems on same machines
• Does not address root causes
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Root Cause Analysis (5 Why’s)
FACT: Black contamination in/on pipe
•Carbon burnt somewhere within machine
•Resin burnt from friction / trapped in hot spot
•Material getting stuck in grooves
•Grooves are being created in the machine
•Machine creates grooves within components
•Machine becomes out of spec
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Root Cause Analysis (5 Why’s)
FACT: Black contamination in/on pipe
•Machine components are not tightened to a standard specification
•There is no torque gun in-house with capability to reach specified torques
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Other Causes
• New parts from supplier(s) received in unacceptable condition for use
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Improve
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Identify Opportunities
• Opportunities for improvement in quantifying and tracking waste for continuous improvement– Better understand past, current, future states for
feedback
• Opportunities for waste reduction– Reduce / eliminate scrap due to contamination
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Opportunities for improvement in quantifying and tracking scrap
• Continue maintenance scrap tracking program– Largest stream of previously uncategorized scrap– Better shows current state of BC issue
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Opportunities for improvement in quantifying and tracking scrap
• Introduce new scrap code for “HV – Contamination”– High Voltage fault is a test to check for a problem– Historically, ~80% associated with foreign contamination– Could be a multitude of things
• Cracks• Voids• Holes• Thin walls
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Opportunities for improvement in quantifying and tracking scrap
• Include reason for scrapping mix batches when transferring data from daily logs to high-level spreadsheet– Reason given on daily logs– Not given on high-level spreadsheet– Already spreadsheet rows for reason
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Waste Reduction Opportunities
• Standardized procedures for:– Assembly / Maintenance of central units (CUs)– Inspecting / Cleaning of newly received
components prior to installation
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Assembly/Maintenance of CUs
• Purchase torque gun capable of ~5000 lb-ft
• Torque specs– CU Housing (Cage)– Hydraulic Cylinders– Feed blocks– Shuttle housings
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Inspecting/Cleaning of New Parts
• Formalize inspection of new parts
• Utilize parts washer when needed
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Economic/Environmental BenefitsRecommendation Annual Waste
reduced (kg)
Implementation
Cost
Net
Annual Savings
Payback
Period
Status
Standardize Procedures for
Central Unit Maintenance
18,000 $10,000 $85,000
annually
< 3 months In Progress
Standardize Procedures for
Inspecting / Cleaning parts
200 $140 $950
annually
< 2 months Recommended
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Personal Benefits
• Six Sigma Experience
• Experience facilitating cross-functional team
• Problem Solving Approaches
• Project Management Experience
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Special Thanks to…