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Sscasestudy
ABC Incorporated (ABC) is not achieving Six Sigma quality levels for all critical
Body-Side Sub-Assembly dimensions as requested by their customers.
200000
DPM
150000
Dimension DPM
100000
ASM_7Y 172475
ASM_8Y 85824 50000
ASM_3Y 19786 0
ASM_10Y
ASM_7Y
ASM_8Y
ASM_3Y
ASM_9Y
ASM_6Y
ASM_9Y 3874
ASM_10Y 776
ASM_6Y 4
Ensure that all critical body-side subassembly dimensions are within Six Sigma
quality levels of < 3.4 DPM. Cp 2.0 and Cpk 1.67.
ABC Incorporated’s customer wants ABC to apply Six Sigma problem solving
methodology to insure that the body side subassembly is achieving Six Sigma quality
levels of less than 3.4 defects per million for all critical body side subassembly
dimensions.
ABC needs an improvement strategy that minimizes the rework costs while achieving the
desired quality objective. ABC’s goal is to produce module subassemblies that meet the
customer requirements and not necessarily to insure that every individual stamped
component within the assembly meets it original print specifications – sub-system
optimizations vs. local optimization.
A-Pillar B-Pillar
Reinforcement Body Side Outer Reinforcement
+
+
3
Measure Phase D M A I C
Define Measure Analyze Improve Control
Key Variables:
Assembly process variables:
Weld Pattern (density), Clamp Location, and Clamp Weld Pressure
Stamping process variables (body side):
Press Tonnage, Die Cushion Pressure, Material Thickness
172475
DPM
150000
100000 85824
50000
19786
3874
776
4
0
ASM_7Y ASM_8Y ASM_3Y ASM_9Y ASM_10Y ASM_6Y
4
Analyze Phase D M A I C
Define Measure Analyze Improve Control
5
Analyze Phase D M A I C
Define Measure Analyze Improve Control
Environment
Quality
Component Temperature Operator
Variability
Inputs Outputs
Body Side Sub-Assembly
Material Thickness Body Side Sub-Assemblies at
Stamping Process
Yield Strength Six Sigma quality levels
Error
Noise Variables
States
Environment
Inherent Variation Dimensional
defects
6
Analyze Phase D M A I C
Define Measure Analyze Improve Control
1.0
ASM_8Y
ASM_7Y
0.5
0.5
0.0
0.0
2 7 12 2 7 12
Subgroup Number Subgroup Number
Number of runs about median: 4.00000 Number of runs up or down: 6.00000 Number of runs about median: 4.00000 Number of runs up or down: 8.00000
Expected number of runs: 7.00000 Expected number of runs: 7.66667 Expected number of runs: 7.00000 Expected number of runs: 7.66667
Longest run about median: 5.00000 Longest run up or down: 3.00000 Longest run about median: 5.00000 Longest run up or down: 2.00000
Approx P-Value for Clustering: 0.03464 Approx P-Value for Trends: 0.10778 Approx P-Value for Clustering: 0.03464 Approx P-Value for Trends: 0.59781
Approx P-Value for Mixtures: 0.96536 Approx P-Value for Oscillation: 0.89222 Approx P-Value for Mixtures: 0.96536 Approx P-Value for Oscillation: 0.40219
ASM_7Y
0.5
7
Analyze Phase D M A I C
Define Measure Analyze Improve Control
Capability of B_7Y
Capability Analysis of B_7Y Capability of BS_7Y
Capability Analysis of BS_7Y
Overall Capability Observed Performance Exp. "Within" Performance Exp. "Overall" Performance Overall Capability Observed Performance Exp. "Within" Performance Exp. "Overall" Performance
Pp 2.95 PPM < LSL 0.00 PPM < LSL 0.00 PPM < LSL 0.00 Pp 0.61 PPM < LSL 0.00 PPM < LSL 0.00 PPM < LSL 15.33
PPU 2.49 PPM > USL 0.00 PPM > USL 0.00 PPM > USL 0.00 PPU -0.17 PPM > USL 666666.67 PPM > USL 908706.09 PPM > USL 698400.06
PPL 3.41 PPM Total 0.00 PPM Total 0.00 PPM Total 0.00 PPL 1.39 PPM Total 666666.67 PPM Total 908706.09 PPM Total 698415.39
Ppk 2.49 Ppk -0.17 XY Plot of ASM_7Y and BS_7Y
1.3
1.0
BS_7Y
0.5
Impact this has on ASM dimensions 7Y, 8Y, 9Y & 10Y on Tonnage
Capability Analysis of ASM_7Y at Tonnage > 935 Capability Analysis of ASM_8Y at Tonnage > 935
-1.0 -0.5 0.0 0.5 1.0 -1.0 -0.5 0.0 0.5 1.0
Cpm * Cpm *
Overall Capability Observed Performance Exp. "Within" Performance Exp. "Overall" Performance Overall Capability Observed Performance Exp. "Within" Performance Exp. "Overall" Performance
Pp 2.25 PPM < LSL 0.00 PPM < LSL 0.00 PPM < LSL 0.00 Pp 3.74 PPM < LSL 0.00 PPM < LSL 0.00 PPM < LSL 0.00
PPU 2.05 PPM > USL 0.00 PPM > USL 0.01 PPM > USL 0.00 PPU 4.22 PPM > USL 0.00 PPM > USL 0.00 PPM > USL 0.00
PPL 2.46 PPM Total 0.00 PPM Total 0.01 PPM Total 0.00 PPL 3.26 PPM Total 0.00 PPM Total 0.00 PPM Total 0.00
Ppk 2.05 Ppk 3.26
Capability Analysis of ASM_9Y at Tonnage > 935 Capability Analysis of ASM_10Y at Tonnage > 935
Overall Capability Observed Performance Exp. "Within" Performance Exp. "Overall" Performance Overall Capability Observed Performance Exp. "Within" Performance Exp. "Overall" Performance
Pp 1.88 PPM < LSL 0.00 PPM < LSL 0.00 PPM < LSL 0.00 Pp 1.78 PPM < LSL 0.00 PPM < LSL 0.00 PPM < LSL 0.00
PPU 0.90 PPM > USL 0.00 PPM > USL 10010.77 PPM > USL 3408.51 PPU 1.08 PPM > USL 0.00 PPM > USL 2326.72 PPM > USL 576.00
PPL 2.86 PPM Total 0.00 PPM Total 10010.77 PPM Total 3408.51 PPL 2.47 PPM Total 0.00 PPM Total 2326.72 PPM Total 576.00
Ppk 0.90 Ppk 1.08
Conclusion: Setting Tonnage to greater than 935 resulted in ASM_7Y and ASM_8Y
meeting the goal of <3.4 DPM. ASM_9Y and ASM_10Y require further analysis.
10
Analyze Phase D M A I C
Define Measure Analyze Improve Control
• Optimizer recommends setting Weld Density to 1.33 weld per inch (level 1),
but this appears to be a robust parameter, which could be changed for the benefit
of process without reducing quality if processing time or cost shows a benefit.
• Optimizer recommends setting Clamp Pressure to 2100 psi (level 1), but this
appears to be a robust parameter, which could be changed for the benefit of process
without reducing quality if processing time or cost shows a benefit.
• Run additional tests at recommended settings to confirm results
• Weld Density and Clamp Pressure are robust parameters and can be set to optimize
the process capability to maximum level and lowest cost.
11
Analyze Phase D M A I C
Define Measure Analyze Improve Control
12
Analyze Phase D M A I C
Define Measure Analyze Improve Control
Within
mm mean offset
Target *
LSL -1 Overall
Mean 0
Sample N 36
StDev (Within) 0.0851436
StDev (Overall) 0.0971725
14
Analyze Phase D M A I C
Define Measure Analyze Improve Control
Conclusions
• Setting tonnage > 935 results in ASM_7Y and ASM_8Y meeting the goal
15
Analyze Phase D M A I C
Define Measure Analyze Improve Control
With the recommended changes the process performance will improve significantly
Dimension Mean StDev DPM_Obsv DPM_Within DPM_Exp Pp Ppk Cp Cpk
Overall
ASM_1Y -0.035 0.165 0 0 0 2.01 1.94 2.47 2.39
ASM_2Y 0.259 0.152 0 0 1 2.20 1.63 2.31 1.71
ASM_3Y 0.000 0.097 0 0 0
ASM_4Y 0.009 0.115 0 0 0 2.90 2.87 3.53 3.50
ASM_5Y -0.330 0.145 0 0 2 2.30 1.54 3.72 2.50
ASM_6Y -0.284 0.160 0 1 4 2.08 1.49 2.24 1.60
ASM_7Y 0.090 0.148 0 0 0 2.25 2.05 2.04 1.86
ASM_8Y -0.128 0.089 0 0 0 3.74 3.26 3.27 2.85
ASM_9Y 0.521 0.180 0 0 0
ASM_10Y 0.395 0.191 0 0 0
16
Improve Phase D M A I C
Define Measure Analyze Improve Control
• Re-machine the A-Pillar die to move the mean of A_3Y to nominal which in turn
will move ASM_3Y to nominal
Implement the above recommendations and run additional samples to verify results.
17
Control Phase D M A I C
Define Measure Analyze Improve Control
Recommended controls :
• Implement an alarm and shut-off feature on the body side press if tonnage
falls below 935 tons
18
Summary D M A I C
Define Measure Analyze Improve Control
ABC Incorporated is not achieving Six Sigma quality levels for all critical Body-
Side Sub-Assembly dimensions as requested by their customers. BBM needs to
apply Six Sigma problem solving methodology to establish an improvement strategy
that minimizes rework costs, yet achieves the desired quality objective.
Bring the key process output variables within Six Sigma quality level of < 3.4 DPM.
Cp 2.0 and Cpk 1.67
19