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					      Six Sigma Green Belt Project


         1250-XX Covers
Reduction of Raw Material Cost by Utilizing Regrind

            Green Belt Candidate, Tempe
                     07/13/07
                         -Define-

The purpose of this project is to determine if the blending of 25%
regrind into the GE Ultem 1000 will significantly change the Key
dimensional and visual characteristics of the 1250-XX covers. We will
focus on the 1250-05 for data collection as this is our highest volume
part for this Customer in this category.

If successful, this will eliminate the scrapping of the GE Ultem 1000
runners plus reduce the amount of virgin material necessary to
complete the orders.
-Process Map-
Material Purchasing
                                 -Measure-
                             MSA Instructions
Instructions:
-Using the Zeiss CMM program 1250-05 Six Sigma Post Only, run sample parts in order.
Samples are identified 1-10.
Setup (See pictures below):
Place 1.500” spacer in H2.(2x .750”)
Place .750” spacer in H7. Position 1250-05 sample upside down on spacer with gate at 45
degree angle to the bottom left. Snug down with second .750” spacer.
Follow instructions contained in program for Base Alignment criteria.




     Gate at 45 Degrees
       -Measure-
Measurement System Analysis
              Measurement System Analysis cont’d.
  Less than 10% of the tolerance is taken up by measurement error indicating that
   the Zeiss CMM program is an acceptable way to accurately measure the Key
                                   characteristics.
Gage R&R                                        %Contribution
Source                  VarComp      (of VarComp)

Total Gage R&R          0.0000000    0.99
 Repeatability          0.0000000    0.99
 Reproducibility        0.0000000    0.00
Part-To-Part            0.0000002    99.01
Total Variation         0.0000002    100.00

            StdDev                   Study Var       %Study Var         %Tolerance
Source                  (SD)                     (5.15*SD)      (%SV)                (SV/Toler)

Total Gage R&R          0.0000483    0.0002488    9.95                  2.49
 Repeatability          0.0000483    0.0002488    9.95                  2.49
 Reproducibility        0.0000000    0.0000000    0.00                  0.00
Part-To-Part            0.0004832    0.0024885    99.50                 24.88
Total Variation         0.0004856    0.0025009    100.00                25.01


Number of Distinct Categories = 14
                  -Measure-
Key Dimension Capability using 100% Virgin Material
                  -Measure-
Key Dimension Capability using 100% Virgin Material
                  -Measure-
Key Dimension Capability using 100% Virgin Material
             -Measure-
Key Dimension Capability using 25% Regrind
             -Measure-
Key Dimension Capability using 25% Regrind
             -Measure-
Key Dimension Capability using 25% Regrind
              -Measure-
Key Dimension Capability using 100% Regrind
              -Measure-
Key Dimension Capability using 100% Regrind
              -Measure-
Key Dimension Capability using 100% Regrind
                                  -Analyze-
   A t-Test is being used to show that there is no significant difference in the means
 between the 100% Virgin material and the Virgin material with 25% Regrind. With the
P-value being greater than Alpha (.05), we fail to reject the Null Hypothesis (Ho) on all 3
                                   Key Characteristics.
-Analyze-
  Cont’d.
                                -Analyze-
                                      Cont’d.
Samples were run with 100% Regrind to see what effect it had on the Key Characteristics.
t-Tests were used to show if a significant difference in the means had been caused by the
   change. With P-values remaining greater than Alpha (.05), we fail to reject the Null
   Hypothesis (Ho) on all 3 characteristics proving there is no significant difference in
                    dimensional readings when 100% Regrind is used.
-Analyze-
  Cont’d.
                              -Improve-
The Improvement phase will implement the usage of 25% Regrind added to the virgin
  material during normal production runs. The Work Order template will be updated in
  the Shared Directory to accurately reflect the percentage of regrind allowed. Correct
    usage of material will be verified during the QA Sign-In and initialed. The Bill of
                              Materials will also be amended.
                                -Control-

The Customer defined ‘Key Characteristics’ will be monitored after the introduction of
      regrind during the molding operation using a variety of tools. Sign-In and In-
    Process dimensional inspection criteria are controlled and communicated via the
   Mold Data Book. The QA Sign-In at the start of the run will include the Customers
   current A-079 inspection form available from their Customer Website. In-Process
  data will be entered into real-time SPC Charts in the Quality Control Lab and will be
    monitored by Quality Inspectors. Any unusual variation in the SPC Charts will be
   investigated. Out of specification product will be quarantined and properly labeled
    with an Non Conforming Material Report per the ISO standard and dispositioned
                                        accordingly.
                         -Control-
Copy of Mold Data Book Page-        Copy of Mold Data Book Page-
       Sign-In Criteria        In-process Dimensional Inspection criteria.
          -Control-
Sample Customer A-079 Inspection Form
                   -Control-
                               Copy of Blank NCMR


Sample SPC Chart
-Cost Savings-
                        -Cost Savings-
Extrapolated to include all the 1250-XX Covers that do not specify ‘100% Virgin Only’
                          including -02, -05, -08, -10, -11, -12:
                          -Conclusion-
 After measuring samples run with 25% Regrind/75% Virgin and samples run
      with 100% Regrind, it has been concluded that there were no significant
  differences or changes in the Customer’s Key Dimensions. Cpk levels ranged
   between 2.64 and 9.94 indicating all values are well above the 2.00 Cpk of a
  stable 6-sigma process. Taking into account normal process variation and the
     likeliness that the process may drift, it can be assumed that the values will
                      remain within the Customer’s specifications.
 Tensile strength testing will need to be done by the Customer to verify overall
        strength and integrity has not been compromised due to this change.
With an annual savings of $5,687.34 for the -05 configuration, the potential cost
    savings if applied to all of the 1250-XX part numbers would be $13,655.25
                                       annually.

				
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