Reduction of spillage output of Perros cabinet

foaming updates
Customer Driven Lean Six Sigma CDI-MO Project
Where are we now?
Due to spillage defect alone on our Perros foaming machine we our encountering around 40u to 510u (4% to
49%) decrease in TPY per day affecting our output & financials as well.
OCT-DEC Data of spillage (45days 24hrs Ops)
3,542 out of 28,800 units affected

BAD COST

SCRAP ₱ 10,500.00
MATERIAL (Direct & indirect) ₱ 38,710.00
OPERATING ₱ 19,976.00
REWORK ₱ 278,047.00
≈₱ 347,233.00

Revenue Opportunity Lost (Vol) ≈₱31,000,000.00

Note:
Based on 48days (28,800units output) sample data from Oct-Dec 24hrs run
2
Project Charter
Business Case Problem & Opportunity Statement
Reducing the spillage defect will increase Yield of Perros Throughput Yield at Perros cabinet foaming process is
machine by 10% which generates around ≈₱300,000 130,000ppm (87%) at 28,800units output( 45days 24hrs
(Rework Cost + Operating Cost + Material Savings + Ops from Oct to Dec 2020) versus factory target of 97%
Overtime Savings + Scrap cost + Volume Lost) which is a gap of 10%

Project Scope
Goal Statement This project will focus on spillage issue for Perros
cabinet foaming only
To increase Throughput Yield at Perros cabinet foaming
process from 130,000ppm to 30,000ppm which is a
10% improvement Team Composition
Project Sponsor: Cecille Yap
Champion: George Bandal
Project Leader: Justin Mendoza
Members:
Kristofer Florendo (Process) Mady Lavarro (QA)
Charles Entredicho (CPE) Joel Bundalian (PE)
Lito Portugal (Finance) Renz Nocon (Supervisor JFD)
 0
100
150
200
250
300
400
450
500

350

50
0
01-May-21

Min: 1
0
02-May-21

Max: 29
90
03-May-21

Median: 10
04-May-21

112

44
05-May-21

Spillage Defect
0

Night Shift Foam

06-May-21

0
07-May-21

0
08-May-21

Ave: 12units/day (2.4%)

09-May-21
10-May-21
457

363

11-May-21
12-May-21
337

13-May-21
425

14-May-21
307

Yield
15-May-21
423

16-May-21
112
Day Shift

17-May-21
271

18-May-21
325

Target

19-May-21
171

20-May-21
21-May-21
306293

22-May-21
326

23-May-21
181

24-May-21
25-May-21
419413

26-May-21
322

27-May-21
138

28-May-21
240

29-May-21
123

30-May-21
Perros Machine Yield (MAY)

31-May-21
100
150
200
250
300
350
400
450
500

0
50
162

PRIVATE AND CONFIDENTIAL 01-May-21

02-May-21
03-May-21
04-May-21
Min: 1

Max: 31

05-May-21
Median: 4

06-May-21
07-May-21
08-May-21
09-May-21
Defect

0 0 0 0 0 0 0 0 0 0

10-May-21
11-May-21
Ave: 7units/day (1.4%)

12-May-21
335347

13-May-21
Day Shift Foam Spillage

311

14-May-21
387

Yield

15-May-21
352

16-May-21
17-May-21
249
Night Shift

18-May-21
Target

19-May-21
20-May-21
21-May-21
262

22-May-21
281278 278

23-May-21
24-May-21
368

25-May-21
26-May-21
406413

27-May-21
228

28-May-21
29-May-21
239243

30-May-21
4

31-May-21
379
Measure Phase Roadmap
Continuation of the Breakthrough Strategy®

• KPOVs
• Validate
Performance Data • Baseline Capability • Process Scorecard • Availability of
• Capable • Voice of Process • Quantified Project Resources
• Lowhanging fruit
Measurement • Baseline Control Objectives • BB/Team Training
• Identify major
system on Ys Chart • Validated Financial Needs
sources of
• Data • Z, DPMO Goals • Barriers
variation
Collection/Sampling • Schedule
• Potential KPIVs
Plan • Budget

Validate Define Identify

Capability Objective PHASE Gate
Measurement Sources of
Analysis Performance Reviews
System (Final) Variation

• Process Owner • Detailed PM

• Process Map • Valid Data • Baseline
• Champion • Brainstorming
• Measurement System • VOCs (specs) • Project Goals Final
• BB • Fishbone/CE
Evaluation Review
• MBB • FMEA
• Calibration Studies • Benchmarking
• Project Tracking • Mistake Proof
• Indiv Tool Review
• Documentation • Poka Yoke
• SPCs (Ys and Xs)
• SOP

5
Bayer Foam Troubleshooting
PROCESS MAP

MACHINE RELATED
PROCESS RELATED

7
 FMEA for Foaming Process

Severity
Current Design Controls Action Results

R.P.N.
Detect
Occur
Process/ Potential Effect(s) of Potential Cause(s)/ Mechanism(s) of Recommended Responsibility & Target
Functional Requirement Potential Failure Mode
Step Failure Failure Action(s) Completion Date
Preventive Method Detective Method Actions Taken Sev Occ Det RPN

How severe is the effect on

What are the The risk

How often does cause of

How well can you detect

completed priority
What are the actions to take w number

the customer?

cause of FM
FM occur?
What is the impact on the What are the existing actions for recuing Who's ith the (RPN) is
In what ways can the step go customer if the failure What causes the step to go wrong (i.e., how controls and procedures that prevent either the occurrence of responsible for the recalculated the
What is the step? Purpose of process/step
wrong? mode is not prevented or could the failure mode occur)? the cause or the Failure Mode? the Cause, or recommended action? RPM? Be product
corrected? improving detection? sure to include of the
completion rankings
month/year for:
Severity
mis-alligned flanges -worn out forming roller on affected
forming of cabinet with
resulting to un-even underbend portion
Cabinet Roll flanges for insertion of
1
Forming body liner assy, back
Under bend flanges matting back panel 3 5 None 7 105
and/or BPA to cabinet -machine limitation underbend on long
panel and bottom assy
assembly (spillage) models last "x" sheets of the pallet
-inconsistent/lacking/out of -Position jigs for
initial sealing for possible Spillage on possible manual application/placement of sealing -Kanban with labels
2 Initial Sealing
foam chemical outlets
place sealing
foam chemical outlets
5 materials
10 sealing location
-incoming inspection
6 300
-wrong material type -None
Mating of -force fit assembly
Pre-assembly of cabinet
Cabinet, overlap assembly for Cabinet, spillage on BPA -design tolerance would occur to
3
Bodyliner &
assy with initial sealing
Bodyliner & BPA assembly area
3 manual assembly of matting parts 9 for assembly parts deformation of metal
5 135
for foaming
BPA matting parts
add'l sealing for location
Hotmelt inconsistent/lacking/out of Spillage on hotmelt
4
application
of possible foam
place application application area
5 manual application of hotmelt 10 none incoming inspection 6 300
chemical spillage location

Spillage on final sealing

final sealing for possible inconsistent/lacking/out of manual application of final sealing
5 Final Sealing
foam chemical outlets place application
area of possible 1 materials
6 none none 8 48
chemical outlets
delamination (low
setting ranges from 60 - manual adjustment of pre heating oven
6 Pre Heating
65 deg C
Temparature to high or to low temp) or spillage (high 5 temperature
10 none none 9 450
temp)

-Chemical Temperature too high

-bad pre foam assembly
>Bad pre foam assembly -Pack level too high
spillage on Top,
Cabinet spillage free foamed >Machine parameters not -to much foam in cabinet
7
Foaming cabinet met (Temp and pressure
bottom, back & front 10 -pre heat temp to high
10 8 800
of the foamed cabinet
related) -mold temp to high
-low ration of isocyanate to
masterbatch

8
Pre foamed Cabinet Assembly line Current state

3 2
4
1

CBA & BPA Hot Melt Cab Assy sealing BD sealing

9
Audit Findings on Cab Assy Line
 Weak understanding of operator on Quality Workmanship Standard (QWS)
 No Self management team (before start of shift)
 Review agreement on good and no good judgement
 All processes inspection were on an Attribute measurement
 Suggestion:
 THERMA GUM and HOT MELT process should be converted to a variable measurement process inspection

10
Kaizen Activities

MANUAL MANUAL
MANUAL PROCESS
PROCESS PROCESS MANUAL
PROCESS
3 2
4
1

11
Fisbone Analysis Perros Machine
Foaming Plug Day Tank Mixing Head

Temperature Operating Level Foam Chem Pressure

• Refill • ISO

• Supply • POLY

Day Tank Temp & Foam Chem Temp

pressure • ISO
• ISO
• POLY
• POLY
Perros Foming
machine

Temperature Temperature Temperature Operating Pressure

• Pump Iso

• Pre mix pump Poly & cyclo

• Pump Poly

FLOWRATE Preheating cycle time Operating Temp

• Cooling system

• Tank Iso

• Tank Poly

Pre Mix
Boiler Fixture Pre heat Oven
Station

13
Data Collection Plan Machine Data
Type of Sampling
What to Measure Defect Definition Type of Data Operation Definition Data Collection form
Measure Plan
Sampling would
A visible appearance of cured foam manifested outside
be havested
Spillage Major Spillage Output Discrete the external cabinet perimeter (front-liner, back - back Monitoring sheet via excel
every end of
panel, bottom - bottom panel, top - tapping plate)
shifts
under temp
Defect: water heater 1 temperature Digital Temperature Gauge
reading every 4hrs
Boiler 1 temperature over temp input Continuos, Interval Boiler Std temp: (DTG) data encoded to excel
per shift
BOILER

defect: Spillage 50-55 °C data log sheet

under temp
water heater 2 temperature Digital Temperature Gauge
- reading every 4hrs
Boiler 2 temperature input Discrete Boiler Std temp: (DTG) data encoded to excel
over temp per shift
50-55 °C data log sheet
defect: Spillage
data inputed on
FIXTURE BED

Active fixture/ shift input Discrete fixture that are currently used for production Data Log sheet the start of the
n/a shift
under temp
fixture bed temperature
- Thermogun data encoded to every curing (start
fixtures temperature (1-10) input Continuos, Interval Fixture Std temp:
over temp excel data log sheet & end)
40-45 °C
defect: Spillage
PRE HEAT

under temp pre heating oven temp before entering foaming machine Digital Temperature Gauge
OVEN

- every subo ng
Pre heating oven temp input Continuos, Interval Pre Heat Std temp: (DTG) data encoded to excel
over temp cabinet
65-75 °C data log sheet
defect: Spillage
under pressure
-
ISO chem std operating pressure(injection): 137 +10 bar
Mixing Head

foam chem MH pressure ISO over pressure input Continuos, Interval Data Log sheet Evershot
ISO chem std operating pressure(stand by): 2-5 bar
Defect: spillage

under pressure
- ISO chem std operating pressure(injection): 155 +10 bar
foam chem MH pressure Poly input Continuos, Interval Data Log sheet Evershot
over pressure ISO chem std operating pressure(stand by): 1-3 bar
Defect: spillage 14
Data Collection Plan Machine Data

15
Project steps & help needed
MEASURE PHASE
 Strengthen FMEA
 Analyze possible Lean implementation on pre foam process
 Establish Data based on data collection plan for Perros machine inputs
 Process Capability
 Project Goals Calibration on Target Date

Help Needed
 Weekly scheduled day for LSS project activities

16
Thank you