Beruflich Dokumente
Kultur Dokumente
1250-XX Covers
Reduction of Raw Material Cost by
Utilizing Regrind
Green Belt Candidate, Tempe
07/13/07
-DefineThe 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.
-MeasureMSA 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
By Part ID (Oper.)
Percent
100
%Contribution
%Study Var
%Tolerance
50
2.8015
2.8010
2.8005
2.8000
0
Gage R&R
Repeat
Reprod
Part ID
Oper.
Part-to-Part
R Chart by Oper.
Sample Range
0.00015
Biljana
Kelley
By Oper.
Mike
UCL=1.52E-04
0.00010
2.8015
2.8010
0.00005
R=4.67E-05
2.8005
0.00000
LCL=0
2.8000
Oper.
Sample Mean
Zeiss
5-25-07
K. Miller
.010
Biljana
Kelley
Mike
UCL=2.801
Mean=2.801
LCL=2.801
2.801
2.800
Biljana
Kelley
Mike
VarComp
%Contribution
(of VarComp)
0.0000000
0.0000000
0.0000000
0.0000002
0.0000002
0.99
0.99
0.00
99.01
100.00
Source
(SV/Toler)
StdDev
%Tolerance
(SD)
0.0000483
0.0000483
0.0000000
0.0004832
0.0004856
Study Var
(5.15*SD)
0.0002488
0.0002488
0.0000000
0.0024885
0.0025009
%Study Var
(%SV)
9.95
9.95
0.00
99.50
100.00
2.49
2.49
0.00
24.88
25.01
2.8017
Capability Histogram
UCL=2.802
Mean
2.8016
Mean=2.802
2.8015
2.8014
LCL=2.801
2.8014
Subgr 0
10
15
Range
0.00024
2.8016
0.00016
0.00008
R=6.92E-05
0.00000
LCL=0
2.8014
Last 15 Subgroups
2.80165
Values
2.8015
Overall
StDev: 0.0000646
Pp:
25.79
Ppk:
7.61
2.80145
2.80135
0
10
Subgroup Number
15
2.8016
Capability Plot
Within
StDev: 0.0000614
Cp:
27.17
Cpk:
8.01
2.80155
2.8015
Process Tolerance
Within
III
Overall
I
2.793
III
Specifications
2.803
Mean
Capability Histogram
UCL=0.1380
0.1378
Mean=0.1377
0.1376
0.1374
LCL=0.1373
0.1372
Subgr 0
10
15
Range
0.0006
0.1376
0.0004
0.0002
R=1.81E-04
0.0000
LCL=0
0.13750
Last 15 Subgroups
0.1378
Overall
StDev: 0.0001786
Pp:
3.73
Ppk:
3.10
0.1376
0.1374
0
10
Subgroup Number
15
0.13775
0.13800
Capability Plot
Within
StDev: 0.0001606
Cp:
4.15
Cpk:
3.44
0.1380
Values
0.1380
Process Tolerance
Within
I
I
I
0.136
Overall
I
Specifications
0.140
0.0074
Capability Histogram
UCL=0.007337
Mean
0.0072
Mean=0.007065
0.0070
0.0068
LCL=0.006793
0.0066
Subgr 0
10
15
0.00030
0.00015
R=1.45E-04
0.00000
LCL=0
0.00680
Last 15 Subgroups
0.0071
Overall
StDev: 0.0001202
Pp:
13.87
Ppk:
8.14
0.0069
0.0067
0
10
Subgroup Number
15
0.00705
0.00730
Capability Plot
Within
StDev: 0.0001281
Cp:
13.01
Cpk:
7.63
0.0073
Values
0.0074
UCL=4.72E-04
0.00045
Range
0.0070
Process Tolerance
Within
II I
Overall
II I
0.00
Specifications
0.01
2.8015
Capability Histogram
UCL=2.801
Mean
2.8014
Mean=2.801
2.8013
2.8012
LCL=2.801
1
Subgr 0
10
2.80100
15
2.80125
2.80150
0.0003
Range
UCL=2.62E-04
0.0002
0.0001
R=8.01E-05
0.0000
LCL=0
2.8011
Last 15 Subgroups
Values
2.8013
Overall
StDev: 0.0000894
Pp:
18.65
Ppk:
6.26
2.8012
2.8011
0
10
Subgroup Number
15
2.8015
Capability Plot
Within
StDev: 0.0000710
Cp:
23.47
Cpk:
7.88
2.8014
2.8013
Process Tolerance
Within
III
Overall
I
2.793
III
Specifications
2.803
Capability Histogram
Mean
0.13775
UCL=0.1377
0.13750
Mean=0.1374
0.13725
0.13700
LCL=0.1370
0.13700
Subgr 0
10
15
0.0004
0.0002
R=1.95E-04
0.0000
LCL=0
0.1370
Last 15 Subgroups
0.1374
Overall
StDev: 0.0001758
Pp:
3.79
Ppk:
2.60
0.1372
0.1370
0
10
Subgroup Number
15
0.1374
0.1378
Capability Plot
Within
StDev: 0.0001728
Cp:
3.86
Cpk:
2.64
0.1376
Values
0.13750
UCL=6.37E-04
0.0006
Range
0.13725
Process Tolerance
Within
I
I
I
0.136
Overall
Specifications
0.140
Capability Histogram
Mean
0.00735
UCL=0.007317
0.00710
Mean=0.006979
0.00685
LCL=0.006640
0.00660
0.0066
Subgr 0
10
15
0.0006
Range
0.0071
0.0004
0.0002
R=1.80E-04
0.0000
LCL=0
0.0066
Last 15 Subgroups
0.00730
Overall
StDev: 0.0001662
Pp:
10.03
Ppk:
6.06
0.00705
0.00680
0
10
Subgroup Number
0.0071
15
0.0076
Capability Plot
Within
StDev: 0.0001597
Cp:
10.44
Cpk:
6.31
0.00755
Values
0.0076
Process Tolerance
Within
I II
Overall
III
0.00
Specifications
0.01
2.8018
Capability Histogram
Mean
UCL=2.802
2.8016
Mean=2.801
2.8014
LCL=2.801
2.8012
2.80120
Subgr 0
10
15
2.80145
2.80170
Range
0.0003
0.0002
0.0001
R=1.10E-04
0.0000
LCL=0
2.80120
Last 15 Subgroups
Values
2.8018
2.8016
2.8014
2.8012
0
10
Subgroup Number
15
2.80145
2.80170
Capability Plot
Within
StDev: 0.0000975
Cp:
17.10
Cpk:
5.19
Process Tolerance
Within
Overall
StDev: 0.0001271
Pp:
13.12
Ppk:
3.98
Specifications
III
Overall
I
2.793
III
I
2.803
Capability Histogram
UCL=0.1378
Mean
0.1378
0.1376
Mean=0.1375
0.1374
LCL=0.1372
0.1372
0.13720
Subgr 0
10
15
0.13745
0.13770
0.0006
Range
UCL=5.24E-04
0.0004
0.0002
R=1.60E-04
0.0000
LCL=0
0.13720
Last 15 Subgroups
Values
0.1378
0.1376
0.1374
0.1372
0
10
Subgroup Number
15
0.13745
0.13770
Capability Plot
Within
StDev: 0.0001422
Cp:
4.69
Cpk:
3.55
Process Tolerance
Within
Overall
StDev: 0.0001915
Pp:
3.48
Ppk:
2.64
Specifications
I
I
0.136
Overall
I
0.140
Mean
0.0072
Capability Histogram
UCL=0.007158
0.0070
Mean=0.006941
0.0068
LCL=0.006723
0.0066
0.00660
Subgr 0
10
15
0.00685
0.00710
0.00045
Range
UCL=3.78E-04
0.00030
0.00015
R=1.16E-04
0.00000
LCL=0
0.00660
Last 15 Subgroups
Values
0.0072
0.0070
0.0068
0.0066
0
10
Subgroup Number
15
0.00685
0.00710
Capability Plot
Within
StDev: 0.0001026
Cp:
16.24
Cpk:
9.94
Process Tolerance
Within
Overall
StDev: 0.0001186
Pp:
14.05
Ppk:
8.60
Specifications
III
Overall
II I
0.00
0.01
-AnalyzeContd.
-AnalyzeContd.
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.
-AnalyzeContd.
-Cost Savings-
-Cost SavingsExtrapolated to include all the 1250-XX Covers that do not specify
100% Virgin Only including -02, -05, -08, -10, -11, -12: