201

10 .- . . 21150
038-683-393-7

075-538111
Email
surasale@scg.co.th
Website www.scg.co.th/chemicals

" "

PM Analysis
Multi-vari Chart Taguchi L-18
QC Story

(SD) 50%
50%

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 203

spec

spec

TPM (Total Productive Management)

Operational Excellence Quality /
Cost / Delivery / Safety / Moral & Environment Focus
Improvement
project
Focus Improvement
Project project (FI small
group) simple tool (7 QC Tools)
project engineer

(spec)
4

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The 11th Symposium on TQM-Best Practices in Thailand

2009 project


0.08% 0.04% ( 50%)

multi-vari chart

2 MSA (Measurement system analysis)

regression (factor) :
(bulk density)
PM Analysis (condition)

Design of Experiment (DOE) Taguchi L-18

2
8

2

0.08%
0.04%


2

(Inspection check sheet)
(visual control)

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(TPE)
(SCGPolyolefins Co, Ltd) (SCGChemical)
1 6 (SCG)
TPE (PE) (PP)

Polyolefins Value chain

TPE .. 2532
1.1 2009 2010
1.8
50% 50%
TPE ISO 9001,
ISO 14000, TIS/OHSHA 18001, ISO 17025 Deming Application Prize
2004 TPM Excellent 1st Category 2007 TPE
(Operational Excellence)

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The 11th Symposium on TQM-Best Practices in Thailand

TPE

(Enlarge economy scale)

(Enrich value creation, synergy)

(Enable capability & strength utilization)

 207

(Embed knowledge and culture for future growth)

4

(Open)
(Challenge)
SCG People
SCG

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The 11th Symposium on TQM-Best Practices in Thailand

(Introduction)
TPE SCG Chemicals
TPM (Total Productive Management)
(Operational Excellence)
TPM Special Award 2010
Loss Tree Focus Improvement (KK) 2009
(Loss) (Raw Material Cost)

7 Steps Problem Solving (QC Story)

1. (Problem Selecting)
Loss Tree Raw Material Cost Loss

4
(spec)

Process Capability
(1.4 Z scroe) Raw material loss
( ~ 1%)
(rework)

( Raw material
loss)
()
""

 209

(Observation)

Silo (Weight Scale) 2
A B (Weight Scale) shutter 2
shutter

shutter 1
shutter
(seal)
(Conveyer) (Weight Checking)

(pallet)

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The 11th Symposium on TQM-Best Practices in Thailand

 211

, Silo (Level Silo) Lot

MultiVari Chart
(weight scale A,B)
(Level Silo) Lot

3. (Taget & Plan setting)

(50%)
(Process Capability > 1.00)

5 ( 50%)

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The 11th Symposium on TQM-Best Practices in Thailand

4. Analysis

Why-Why Analysis

6 Why-Why Analysis

Why-Why Analysis

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1.
5 (subgroup size n=5)
14

2. Weight Scale A, B
(Weight Scale) A B
50 2 Sample T-test & 2 Variance Test
(Weight Scale) A
B 95% (P-Value < 0.05) (Variation)
A B
(Weight Scale) A B
()
(Mean) (SD)
DOE (Design of Experiment) (Optimal Condition)

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The 11th Symposium on TQM-Best Practices in Thailand

3. Shutter
Line (Line #1) Shutter Weight Scale
(Cylinder)

Line #4 Shutter Steping Motor

Line #4 Line #1

 215

4. Weight Scale
(3 Gen ) (Weight Scale) A
(Shutter Cylinder)
B
(Vibration) A
B A (vibration) B

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The 11th Symposium on TQM-Best Practices in Thailand

5. (stock) Hopper Silo

Hopper Silo (Weight
Scale) (Gravity flow) Hopper
(Transfer Pressure)
(Plant) Hopper

 217

- (Countermeasure)
Why-Why Analysis

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The 11th Symposium on TQM-Best Practices in Thailand

1. Weight Scale A ? B
(Factors)
(Weight Scale) A B (Optimal Condition Setting)
Design of Experiment (DOE)
8
DOE Taguchi L-18
DOE (Main Factor)
(Mean) Set Point A B (Variation) Discharge A B

DOE (Optimal Condition Setting) Weight Scale A = B

 219

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The 11th Symposium on TQM-Best Practices in Thailand

Weight Scale
A B A B

2.
Regression
Lot
Tare

 221

3. Shutter

(Modify) Shutter
(Cylinder) Stepping motor

4. Weight Scale
Shutter Cylinder
(Weight Scale) A B
(vibration) Weight Scale A B PM Analysis
(Condition)

(Vibration) (Condition)
(Pressure) Cylinder Shutter

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The 11th Symposium on TQM-Best Practices in Thailand

PM Analysis (PM)

(Vibration) (Weight Scale) A B

 223

5. (Stock) Hopper Silo

(Program interlocks)
(Weight Scale) stock Hopper
6. (Check Result)
4

50% (Target)
(Process Capabilty)
Ppk = 1.17 (Ppk > 1)
~1% ~ 200 ppm (0.02%)

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The 11th Symposium on TQM-Best Practices in Thailand

7. (Standardization)



(speed shutter)
(Tare) (weight checking)
(Visual Control)

(Benefit)
(Tangible Benefit)

(Raw Material Loss)
50% (Cost Saving) ~ 2
(Intangible Benefit)
7
Step QC Story

-
1.
TPE

SCG
2.
QM

 225

1. TPE


TPM
2. TPE TPM QCC
2 /

/ 7 Steps QC Story

3. 1
TQM Expert & Problem Solving Guru SCGOperational Excellence OE Internal Consultant
Change Agent TQM

(2551)
:
Bhote, K. R., & Bhote, K. A. (2000). World class quality: Using design of experiments to make it happen. New York: AMACOM.

www.ftqm.or.th