Scrap Convergence Plan Wuhan lens line #1 Update Feb 5 th Frédéric MORET Feb 5, 2007.

Scrap Convergence PlanWuhan lens line #1Update Feb 5th

Frédéric MORETFrédéric MORETFeb 5, 2007

Property of Valeo – Duplication prohibitedJanuary 2005

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Scrap Convergence Plan – Wuhan lens line #1Background

Wuhan lens line #1 results were: > 50% scrap rate

< 40% normal capacity

since it started in April 2006

Wuhan Saico Single Lens Production and Scrap Trend

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Mold Scrap 18,7% 28,9% 11,6% 26,0% 11,7% 18,7% 12,3% 10,8% 10,3% 9,8% 11,8% 12,0% 10,8%

Coat Scrap 58,6% 33,3% 20,9% 43,4% 47,1% 41,3% 51,8% 49,6% 46,8% 42,0% 39,8% 47,0% 45,1%

Total Scrap 77,3% 62,2% 32,5% 69,4% 58,8% 60,0% 64,1% 60,4% 57,1% 51,8% 51,6% 59,0% 55,9%

Real Production 2117 1988 7669 2549 2808 2430 3509 2763 5295 5123 5407 8777 5820

Planned Production

22-Sep 29-Sep 6-Oct 13-Oct 20-Oct 27-Oct 3-Nov 10-Nov 17-Nov 24-Nov 1-Dec 8-Dec 15-Dec 22-Dec 29-Dec


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Scrap Convergence Plan – Wuhan lens line #1 Background

VLS fast recovery plan

20% scrap rate target by end of Jan 07 for Wuhan lens line #1

Branch coating specialist staying in Wuhan forcing results

No recorded scrap improvement after 2 months

Decision to launch scrap convergence plan on Jan 3 in order to achieve VLS fast recovery plan target

5. Scrap reduction J. Gregory

Conf call every 2 days with team in Wuhan to force results J. Gregory

Continue implementation and assure A. Chenet stays in Wuhan until result is achieved - Will stay until 12/20 then back after hoilidays

A. Chenet - Branch coating

specialistCheck each action and assure on track and effectively implemented - force immediate reaction if not on track - doing it but no scrap recorded improvement yet Stay on the system and force results

A. Chenet - Branch coating

specialist

Action - ObjectiveResults week -1

Wuhan Lens Scrap - fully implement STOP Scpap/IRIS to reduce average scrap rate from 50% to 20% by end of January

Cat

eg

ory

Action week +1 Responsible


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Scrap Convergence Plan – Wuhan lens line #1 Scope To reduce Wuhan lens line #1 average scrap rate:

From >50 to 20% from February 1st, 2007

From 20 to 10% from April 1st, 2007

Include trainings & networking to keep consistent results over time

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WuHan SaiCo Sigle Lens Production and Scrap Trend

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Mold Scrap 11,7% 18,7% 12,3% 10,8% 10,3% 9,8% 11,8% 12,0% 10,8% 11,2% 10,0% 11,8% 11,8% 13,8% 10,2% 7,4%

Coat Scrap 47,1% 41,3% 51,8% 49,6% 46,8% 42,0% 39,8% 47,0% 45,1% 43,0% 31,5% 41,7% 30,3% 28,0% 29,1% 15,9%

Total Scrap 58,8% 60,0% 64,1% 60,4% 57,1% 51,8% 51,6% 59,0% 55,9% 54,2% 41,4% 53,5% 42,0% 41,8% 39,3% 23,3%

Real Production 2808 2430 3509 2763 5295 5123 5407 4455 3820 4386 6824 3900 6621 6679 7119 9966

Real Production

W42 W43 W44 W45 W46 W47 W48 W49 W50 W51 W52 W01 W02 W03 W04 W05

Scrap Convergence Plan – Wuhan lens line #1 Latest scrap & production weekly results

Close to target before Feb 1st

Arrival of Branch team. Reduction of cycle times

W2 & 3: Trials & tunings

resulting in scrap


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Scrap Convergence Plan – Wuhan lens line #1 Agenda of presentation

Step II: Achievements & status Team, organization & trainings

Capacity

Equipment

Molding

Coating

Inspection

Step III: Action plan & expected results


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Scrap Convergence Plan – Wuhan lens line #1 Team

Name Company Function Office Involvt January February

4/1

5/1

6/1

7/1

8/1

9/1

10/1

11/1

12/1

13/1

14/1

15/1

16/1

17/1

18/1

19/1

20/1

21/1

22/1

23/1

24/1

25/1

26/1

27/1

28/1

29/1

30/1

31/1

1/2

2/2

3/2

4/2

Team mgt F. Moret Valeo Management Bobigny 100%D. Daï Valeo Plant mgt Wuhan 30%Q. Zhou Valeo APU mgt Wuhan 50%C. Jinsong Valeo Supervisor Wuhan 100%

Coating F. Kanazawa Valeo Process Bobigny 100%process & A. Chenet Valeo Process Bobigny 100%equipment J.P. Dubois Valeo Process Bobigny 100%

G. Vottero Valeo Equipment Pianezza 80%M. Bourgeois Valeo Equipment Wuhan 25%M. Delorme Valeo Purchasing Wuhan 10%E. Dai Valeo Purchasing Wuhan 10%W. Wang Valeo Process Wuhan 50%W. Yang Valeo Maintenance Wuhan 30%

Jig toolmaker Equipment Wuhan 100%Jig toolmaker Equipment Wuhan 100%

Molding M. Hugol Valeo Process Bobigny 100%process & A.A. Racaud Valeo Process Bobigny 100%equipment J. Ortiz Valeo Process Wuhan 50%

J. Truong Valeo Process Wuhan (VIE) 100%N. Castellino Valeo Process Wuhan (VIE) 100%M. Bourgeois Valeo Equipment Wuhan 25%R. Pehl Valeo Purchasing Bobigny 5%M. Delorme Valeo Purchasing Wuhan 5%

MEP Process China 100%FKK Equipment China 100%Toolmaker Equipment China 100%

Quality C. De Poncins Valeo Industrial Bobigny 100%inspection M. Li Valeo VPS Wuhan 100%

Z. Luo Valeo Quality Wuhan 100%

Arrival of Branch team

in Wuhan

Decision for new

organization

Integration of 2 jig makers

2 people in charge of

new T21 jigs

Production of W5 totally managed by Wuhan

team without any support of Branch team


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Scrap Convergence Plan – Wuhan lens line #1 Organization

« Product » APU organizationsince Sept 1, 2006

People having backgroundto manage lens line

Change in organization since Jan 26, 2007 to restore « process » APU structure

Champion for lens line

scrap reduction

Champion for HL

assembly

Future Champion for

lens scrap reduction to be

coached by present one


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Scrap Convergence Plan – Wuhan lens line #1 Trainings Trainings done

In meeting room– 5 courses

Reaction modes for:– Molding defects– Grain defect (varnishing)– Fallen lens & varnish dot defects (varnishing)

Inspection– IRIS– Lens inspection

– 30-35 people attending each time

OJT– 5 trainings

Supplier for jig manufacturing Production team for jig tuning Production team for molding Maintenance team Quality inspection


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Scrap Convergence Plan – Wuhan lens line #1 Documentation

Database All results &

documents related to this plan, including updated action plans

All data related to lens line & its maintenance

Booklet Reaction modes Working instructions Main messages of

trainings


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Scrap Convergence Plan – Wuhan lens line #1 Organization

Further improvements of the team Coaching of line supervisor by APU manager

Varnishing method engineer position to fill


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Scrap Convergence Plan – Wuhan lens line #1 Capacity

Capacity issue because of low « real » TRS

Snowball effect Not enough capacity No time to improve More inefficiency

1st priority has been to recover capacity and to use it for improving: Reduce injection cycle time (-24%) Reduce changeover time by

installing a fork on press platen (-30%)

Learn team how to avoid stoppages Do not accept new product trials

which are not mandatory

Maintenance overtime

3%Changeover

overtime17%

Stoppages13%

Over cycle time18%

Scrap27%

TRS22%


3%Changeover

overtime17%

Stoppages6%

Over cycle time0%

Scrap30%

TRS44%


1%

Changeover overtime

10%Stoppages1%

Over cycle time0%

Scrap18%

TRS70%


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Scrap Convergence Plan – Wuhan lens line #1 Equipment

No major issue on equipment & maintenance Haitian press & Wittmann robot

– No major issue

– Maintenance action plan done: Hot runner heater changed, robot gear changed

Saico line– No major issue

– Maintenance globally well done

– Maintenance action plan done: 13 improvements, detailed maintenance documents


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Scrap Convergence Plan – Wuhan lens line #1 Achievements & Status

Molding Molds

– X11J: No major issue

– R23: Small crack issue, solved by team (change in tool)

– T21: Silver streak (5%) because of poor design & making of tool, cannot be solved by process, needs a tool improvement (on-going action plan). Design of new tool (expected by end of March) checked.

Operation– Black dot scrap reduced by avoiding stoppages and respect of re-

start instruction


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Coating Jigs

– For all: poor making and bad tuning In-feed conveyor: All jigs tuned as well as possible, new jig

design tested on Feb 1st

Varnishing conveyor: – X11J & R23: Tuning of jig improved– T21: New design of jig tested, complete new set done,

installed on Feb 1st

Process– No major issue, some flow-coater tunings have been improved

Operation– Bad jig design and tuning results in many door opening (to set

lens on jig) and so many grain and varnish dot defects. Improved by team, still possible to improve.


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Scrap Convergence Plan – Wuhan lens line #1 Jig sub-project Design & manufacturing of new

T21 jigs as a project

Selection of supplier (8 visited), 1 selected

– Good design & manufacturing means, but no autonomy in design & manufacturing

Training of supplier for design, prototyping & manufacturing

Making & test of prototype 1: OK

Making & test of prototype 2 (simplified design): OK

Making of complete set

Installation & tuning of complete set on Feb 1

Detailed manufacturing instruction provided


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Quality inspection & logistics

IRIS– Badly known and implemented resulting in overquality. Training provided, tools updated.

Production quality– Defects badly known by operators. No inspection standard per product. Setting of operator training

by quality each 2 weeks. Update of all inspection standards.– Re-organization of line quality, in order upstream quality engineer is now in charge of auditing

quality of all actions on the line.– QRAP restarted. – Rules for standard reaction defined (line QRQC). Action plan defined with quality, time schedule to

be defined with APU manager and supervisor.– Line management: Display boards re-organized to provide just necessary up-to-date information

Logistics– Use of cardboxes, plastic bags and foam sheets for packaging WIP lenses resulting in many wastes

(operator time, footprint, scrap, packaging materials). Was limitating cycle time reduction. Replaced by standard lens plastic totes.

Scrap follow-up sheet (Kosu sheet)– Sheet updated for defect definition (more precise), removal of injection trial shots. Change to be

made to remove a mistake in fallen part calculation.

STOP Scrap– Standard display of trend charts and action plans for X11J and T21. Definition of scrap

convergence plan actions according to STOP Scrap system.


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Scrap Convergence Plan – Wuhan lens line #1 Step II

Main issues remaining on Jan 22 Varnish dot defect on T21 (18% of total scrap)

– Only solution is new jig (tested, production of complete set followed-up by Marc Bourgeois)

Grain defect on X11J (16% of total scrap)– Closed door operation (to be followed-up by supervisor)

Silver streaks on T21 (9% of total scrap)– Injection process parameters to be developed by Maxime Hugol

Fallen parts on all products (7% of total scrap)– Robot & jig tuning (to be followed-up by supervisor)

Stoppages, maintenance & changeover delays (5% of total scraps, 40% of productive time)

– Short mold changeover device to be used, maintenance & operation management (to be followed-up more closely by maintenance manager & supervisor)


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Scrap Convergence Plan – Wuhan lens line #1 Step II Roadmap defined on Jan 22

W4: Closed door operation for X11J, jig tuning for fallen parts, closer management to reduce stoppage & changeover times

W5: New jig for T21, new injection process parameters for T21, jig tuning for fallen parts, closer management to reduce stoppage & changeover times

W6 & W7: Tunings to decrease rate of other scraps

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Scrap (%)

Stop (%)

TRS (%)

Scrap (%) 40 32 22 20 18

Stop (%) 40 30 13 13 13

TRS (%) 36 47 68 70 72

W3 W4 W5 W6 W7


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Scrap Convergence Plan – Wuhan lens line #1 Step III To reduce Wuhan lens line #1 average scrap rate:

From 20 to 10% from April 1st, 2007

Definition of action plans in progress

2nd period of Branch team defined (3 weeks in March)

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Scrap Convergence Plan Wuhan lens line #1 Update Feb 5 th Frédéric MORET Feb 5, 2007.

Documents

Transcript of Scrap Convergence Plan Wuhan lens line #1 Update Feb 5 th Frédéric MORET Feb 5, 2007.