Project Name : setup reduction improvement for Tempus auto line Value center :XXXX shenzhen Champion : MBB: XXXXXX.Gutie BB : XXXXX. Ii XXXXXXXX.com,As Tempus products is the key products series for our company, tempus auto-line products sales is 30% of our whole sales. The operation manager proposed to carry on Setup reduction project on Tempus automatic line .and then we build strong improvement team . We started by collecting current setup & changeover time for Tempus M2 machine, and we collected historic data as baseline . finished financial saving under fianc approval. we record M2 Machine setup whole process by digital video. documentation all events for all setup process. separation external time and internal time. convert internal time to external time by team brain storming and watching video by eliminate adjustment during setup. Finally , we review process CPK, again, and document all improvement result . Issue new setup & change over instruction .,Executive Summary,What is the background of this project? 1.Tempus output is about 30% of whole company sale achievement. 2.the customers demand is increasing. 3.As following requirement, but our tempus machine set up time about 3.5h, limits. Tempus production capacity and quick response to customer. auto line manufacturing process scrap rate is 0.98% 4.The requirement of general target of company (efficiency improvement, scrap reduction) What may the project be focused on? 1. increase assembly efficiency ( setup reduction) 2. Scrap reduction in the manufacturing process What are the risk and challenges? Team member time limitation. Process engineer and black belt are new to the company, not much of experience Production line burden is heavy. But project will take up some production time. Lack enough support of team member Project goal & objectives Process improvements in machines M2, M1, M3 and F2 Reduce setup time form 3.5hours to 2 hours Scrap rate reduction: from 0.98% to 0.78% Improve technician SMED knowledge, and production line spare parts & tool management 5S. Project Timeframe Start: 2006-June 17th End: 2006-sep 6th,- Define,Problem Statement/问题描述,Team member/团队成员,- Define,详见：,Project schedule,The scrap rate baseline for Tempus auto line,Identify Baseline,0.2% reduction,Define,the change over&setup time baseline for Tempus auto machine M2,1.5 HOURS,PDF Form/完成PDF表,- Define,Process Mapping/流程分析,The automatic line has 4 workstations,Preparing material,Finished goods,Key process,- Measure,Packing on packing M/C,Machine setup / changeover takes 3.5hours About 2 time changeover are done in 1day,June 1june 6 scrap condition.,Insertion contacts on assemble M/C,Print mark on printer,scrap,Setup & changeover,Electrical test,NG,OK,Tempus automatic assemble machine,Insulation scratch is most high percent,Changeover and setup for the 3 units,1.In alll different type defects and scrap . 2.We need spend 3.5 hours to setup the 4 assembly units to prepare the new production order.,Current setup documentation worksheet,- Measure,According with current setup condition , we video recorded the setup process and finished the documentation worksheet.,MSA/量测系统的分析,- Measure,Gage R&R Study - ANOVA Method Gage name: contacts height measure tools Date of study: June-10-2006 Reported by: ping.li Tolerance: 0.01mm %Contribution Source VarComp (of VarComp) Total Gage R&R 0.0000267 6.44 Repeatability 0.0000217 5.23 Reproducibility 0.0000050 1.21 operator 0.0000009 0.21 operator*sample 0.0000041 1.00 Part-To-Part 0.0003877 93.56 Total Variation 0.0004143 100.00 Study?Var %Study?Var %Tolerance Source StdDev (SD) (6?*?SD) (%SV) (SV/Toler) Total Gage R&R 0.0051640 0.030984 25.37 15.49 Repeatability 0.0046547 0.027928 22.87 13.96 Reproducibility 0.0022361 0.013416 10.99 6.71 operator 0.0009296 0.005578 4.57 2.79 operator*sample 0.0020337 0.012202 9.99 6.10 Part-To-Part 0.0196889 0.118134 96.73 59.07 Total Variation 0.0203549 0.122129 100.00 61.06 Number of Distinct Categories = 5,From the Gage R&R value we can find measure system is in good condition , we need not improve it !,Contact height measure gage:,The dimension L is very critical dimension for customer, so we did Gauge R&R for contact height measurement gage.,current Cp, Cpk /control chart,Current CPk of contact height M2: Customer spec. : 6.5+/-0.1mm CPK=1.43 CP=1.71 PPM=3096 过程能力分析可以量测KPOV，也可以量测KPIV，记录要保留，可以作为改善后的一个重要的对比值,- Measure,For Tempus Male connector, the contact height is a key control parameter. From CPk , and cp data ,we can see insertion contacts process show good capacity.,The current assembly process capacity for contacts height.,Refine the critical input/筛选因素,- Analyze,Refine the critical input/筛选因素,- Analyze,From pareto chart we can see contacts chamfer has great effect to product quality ( insulation scratch).,Insulatio