Quality Progress - February 2018 - 41

FIGURE 2

6-month overall equipment effectiveness of machine A012
85%

91%

96%

94%
76%

Percentage

74%

94%
84%
74%

98%

94% 98%

96% 97%

81%

75%

82%
71%

78%

74%

83%

92%

97%

54%

April

May

June

July

Month

Overall equipment effectiveness

Availability

August

Performance

September

Quality level

Considering temperature during the planning process

Quality loss. With the statistics of the
monthly quality records, a Pareto chart of
the detailed failure modes was constructed
(Figure 4, p. 42). An Ishikawa diagram summarizes possible causes for quality loss in
Online Figure 5.
Looking at Online Figures 1-5, six common root causes appeared in each Ishikawa
diagram:
+ Planning method is improper.
+ Changeover method is not lean.
+ Process and layout are not good for
operation.
+ Setup and adjustment work instructions
are wrong or not standard.
+ Operator, planner or technician lack
training.
+ Process not stable.

Increasing and decreasing temperature is a typical characteristic of an injection
molding process. In Figure 3, a cumulative 122 hours of downtime is attributed to the
heating and cooling process, which accounts for 21% of the total availability loss.
In the six months recorded, 51 different materials and 88 different dies were used
in machine A012. These materials must be processed at 34 different temperatures,
but the production plan did not consider temperature. As a result, long changeover
times were required for heating or cooling to a different temperature. The historical
data showed that the biggest temperature gap reached 300° between two changeovers. The temperature increased 150° during the first changeover and decreased
150° to the original temperature during the second changeover.
By rearranging the production plan, the heating and cooling downtime was
shortened considerably, and the total temperature gap decreased from 3,919°C to
1,598°C.
Because cooling time was included in changeover time, it doesn't contribute to the
time savings. Regardless, the organization still achieved a 36.1-hour time savings by
taking just the heating time into consideration, which is equivalent to a 29.6% savings of
heating time (or a 6.2% decrease of total downtime) (Online Table 1).

FIGURE 3

Pareto chart of machine A012's downtime factors (past 6 months)
120%

122

Downtime (hours)

120

110

100

91

98%

100%

99%

100%

100%

60%
42

40%

34

21%

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80%

81%
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Availability-downtime factors

Downtime percentage

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M

qualityprogress.com ❘ February 2018

QP 41


http://www.qualityprogress.com

Table of Contents for the Digital Edition of Quality Progress - February 2018

Seen and Heard
Expert Answers
Progress Report
Mr. Pareto Head
Career Coach
Office Efficiency
The Crown Jewels of Design
Open Lines
Less Is More
ASQ 2018 Six Sigma Resource Guide
Standard Issues
Six Sigma Solutions
Statistics Spotlight
Marketplace
Footnotes
Try This Today
Quality Progress - February 2018 - intro
Quality Progress - February 2018 - cover1
Quality Progress - February 2018 - cover2
Quality Progress - February 2018 - 1
Quality Progress - February 2018 - 2
Quality Progress - February 2018 - 3
Quality Progress - February 2018 - 4
Quality Progress - February 2018 - 5
Quality Progress - February 2018 - Seen and Heard
Quality Progress - February 2018 - 7
Quality Progress - February 2018 - Expert Answers
Quality Progress - February 2018 - 9
Quality Progress - February 2018 - Progress Report
Quality Progress - February 2018 - 11
Quality Progress - February 2018 - Mr. Pareto Head
Quality Progress - February 2018 - 13
Quality Progress - February 2018 - Career Coach
Quality Progress - February 2018 - 15
Quality Progress - February 2018 - Office Efficiency
Quality Progress - February 2018 - 17
Quality Progress - February 2018 - 18
Quality Progress - February 2018 - 19
Quality Progress - February 2018 - 20
Quality Progress - February 2018 - 21
Quality Progress - February 2018 - The Crown Jewels of Design
Quality Progress - February 2018 - 23
Quality Progress - February 2018 - 24
Quality Progress - February 2018 - 25
Quality Progress - February 2018 - 26
Quality Progress - February 2018 - 27
Quality Progress - February 2018 - 28
Quality Progress - February 2018 - 29
Quality Progress - February 2018 - Open Lines
Quality Progress - February 2018 - 31
Quality Progress - February 2018 - 32
Quality Progress - February 2018 - 33
Quality Progress - February 2018 - 34
Quality Progress - February 2018 - 35
Quality Progress - February 2018 - 36
Quality Progress - February 2018 - 37
Quality Progress - February 2018 - Less Is More
Quality Progress - February 2018 - 39
Quality Progress - February 2018 - 40
Quality Progress - February 2018 - 41
Quality Progress - February 2018 - 42
Quality Progress - February 2018 - 43
Quality Progress - February 2018 - ASQ 2018 Six Sigma Resource Guide
Quality Progress - February 2018 - 45
Quality Progress - February 2018 - Standard Issues
Quality Progress - February 2018 - 47
Quality Progress - February 2018 - 48
Quality Progress - February 2018 - 49
Quality Progress - February 2018 - Six Sigma Solutions
Quality Progress - February 2018 - 51
Quality Progress - February 2018 - 52
Quality Progress - February 2018 - Statistics Spotlight
Quality Progress - February 2018 - 54
Quality Progress - February 2018 - 55
Quality Progress - February 2018 - 56
Quality Progress - February 2018 - 57
Quality Progress - February 2018 - Marketplace
Quality Progress - February 2018 - 59
Quality Progress - February 2018 - Footnotes
Quality Progress - February 2018 - 61
Quality Progress - February 2018 - 62
Quality Progress - February 2018 - 63
Quality Progress - February 2018 - Try This Today
Quality Progress - February 2018 - cover3
Quality Progress - February 2018 - cover4
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