Lean Six Sigma Greenbelt Project B - Regrind

TEAM KAIZENTEAM NO 9

VENKATESH SRINIVASANBHAARAT KUMAR PRAVEEN SUGURUUKESH CHAWAL

DMAIC Define:

DEFINING THE PROBLEM: Consumption of extra material Only virgin material used Spruce and Runners were discarded

GOAL: Reduce virgin material consumption.

CONSTRAINTS: Dimensional changes are not significant. torque performance should not go below Cpk/Ppk of 1.25 minimum.

Measure:

Torque Test Capability Minimum breakage torque for Gear and Cam Fixture Gauge repeatability and reproducibility

Analyze:

Dimensional Comparison Torque Capability Comparison Virgin Nylon vs Regrind Relationship of regrind percentage to breakage torque Capability Analysis for Gear and Cam Breakage Gage R&R Study – Nested ANOVA

Improve

Improvements to fixture and test process

Control

Statistical Process Control of Gear and Cam Breakage

Team Assumption

Cost Analysis is given more priority than Cpk. Any Dimensional change less than 0.0005 are considered

insignificant.

DELIVERABLES

CAPABILITY STUDY Cam 25% vs Cam 50%

CAPABILITY STUDY Cam 25% vs Cam 0%

CAPABILITY STUDY Gear 25% vs Gear 50%

CAPABILITY STUDY Gear 25% vs Gear 0%

REGRESSION MODEL

HYPOTHESIS TESTING

ANOVA TEST OF GRR 1 vs GRR 2 - CAM

ANOVA TEST OF GRR 1 vs GRR 2 - GEAR

Economic Analysis

SPC

Conclusion

25 % is better options than 50% and 0%.