6 SIGMA PROJECT

Reduction of Wastage (Mudas) at Injection Moulding

Shop

Project Leader: Muhammad Mahmood Mansoor

Department: Injection Molding DPL-2

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1.DEFINE
1.1 Problem Statement
• 2.3% rejection in the form of lumps in injection molding shop
Main Project Objectives:
• Identification of avoidable and unavoidable rejection categories w.r.t %
• Calculation of rejection % ranges wrt plans.
• Elimination of avoidable rejection through multiple improvements
1.2 Scope of The Project
• Includes all types of rejection from Molding shop Floor

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1.DEFINE
1.3 INITIAL SITUATION
INITIAL CONDITION
% Rej 2.8% rejection %
as per the new
1.20% 0.50% 0.50% 0.30% 0.10% 2021 molds and
3.1% 2.20% 2.00% SKU numbers
2.9% 2.9%
2.7%
2.5%
2.3% 42.20%
2.2% 2.2%
2.0%
51.00%
1.8%

purging during breaks mold changes as per PPC unplanned changeovers

Jan-20 Feb-20 Mar-20 Jun-20 Jul-20 Aug-20 Sep-20 Oct-20 Nov-20 Dec-20 unskilled workers machine breakdown machine startup
mold breakdown material contamination Wrong material mixed
% Rej Linear (% Rej)
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1.DEFINE
1.3 INITIAL SITUATION
2.8% rejection %
as per the new
2021 molds and
SKU numbers

Machine/ Mold
Purging during Mold changeover as Unplanned Mold breakdown +
breaks per PPC changeovers Material
contamination

1.43% 1.18% 0.06% 0.13%

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1.DEFINE
1.4 TARGET SETTING

Months - 2021 Q1 Q2 Q3 Q4
Target (%) 2.8 2.1 2.1 2.1
Achieved (%) 2.1 - - -

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1.DEFINE
1.5 VOICE OF CUSTOMER / CRITICAL FOR QUALITY

Voice of Critical To
Key Specifications
Customer Quality

Rejection during breaks

Reduce the unavoidable
Minimize the unavoidable Rejection of mold changeovers Reduce the % of rejection from
rejection from Injection
rejection Rejection due to machine big machines
Molding Shop
breakdown

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1.DEFINE
1.6 SIPOC (Molding Shop)
Supplier Store

Input PMC

Mold
Process Feeding into hoppers
Loading
Purging Part Setup Production

Rejected parts during OK

Output Purged Material Color Change Parts(Rejected)
production production

Customer Scrapyard Crusher Store

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1.DEFINE
1.7 PROJECT CHARTER

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2.MEASURE
2.1 PROCESS MAP

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2.Test
2.2 CAUSE & EFFECT DIAGRAM
Material
Man

C Dusty material/rejected PMC fed in machine

Unskilled workers operating machine resulting in mold

C breakdown

Rejection(lumps)

C Machine Startup due to Sundays

C Machine stoppage due to breaks

C Machine breakdown because of no preventive maintenance
C Unplanned mold changeovers
C Mold changeovers as per plan
C Mold breakdown due to no proper Preventive maintenance

Method

Machine
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2.MEASURE
120.0% 1600
2.3 PARETO CHART
1400
100.0%
97.4% 98.6% 99.1% 99.6% 99.9% 100.0%
93.2% 95.4%
1200

80.0%

1000

60.0% 800

51.0%
600
40.0%

400

20.0%

200

0.0% 0

Count Commulative %

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2.MEASURE
2.4 FMEA

Potential Potential Effect(s) Responsibility &

Item / Potential Cause(s)/ Mechanism(s) RP Recommended
S.no Failure Sev occ Current Design Controls Det Target
Function of Failure N Action(s)
Mode(s) of Failure Completion Date

MACHINE STOPPAGES DUE TO RUNNING MACHINES DURING

10 NONE 3 180 PRODUCTION
BREAKS BREAKS

PLANNED MOLD CHANGEOVERS 10 MPS 3 180 IDEAL PLAN FOR SKUs PRODUCTION/PPC

UNPLANNED MOLD CHANGEOVERS 3 NONE 5 90 NONE NONE

REJECTION IN
Moulding HIGH COST OF BARREL CHOKE DUE TO
P4 THE FORM OF 6 2 CRUSH SEIVING TOOLS 2 24 NONE NONE
process POOR QUALITY CONTAMINATED CRUSH USAGE
LUMPS

MACHINE BREAKDOWN 2 NONE 1 12 MACHINE PM MAINTENANCE

MACHINE STARTUP AFTER OFFDAY 1 MPS 6 36 NONE NONE

MOLD BREAKDOWN 2 NONE 6 72 MOLD PM TOOL ROOM

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2.MEASURE
2.5 PARETO CHART
120.0%

1200
100.0%
100.0%

89.4%
1000

80.0% 76.2%
800

60.1%
60.0%

600

42.0%
40.0%

400

21.2%
20.0%
200

0.0% 0
1600 2600 650 1050 400 850

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3.ANALYZE
Engineering Rejection
Unavoidable Rejection
85%

Mold Changeover / Machine Startup Purging During Breaks

38% 47%

Planned Quantity
No. Of SKUs
No. Of batches for production
Batch days Depends on
Ranges for
Maximum batch size 10 variables of engineering engineering rejection
combination of these
rejection can be defined. Exact
Cycle times factors
values not possible
Purging on big machines
Purging on small machines
No. Of Moulds

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3.ANALYZE
Plan Min rej % Max rej % Factors min factors max factors
Plan 35000 25001
material consumption 300000 220000
No of SKUs 11 20
High 2.1% 2.8%
No of batches 22 32
Mold/machine breakdown 0 10
Unplanned model changeovers 0 4
Plan 25000 15000
material consumption 195000 160000
No of SKUs 10 18
Average 2.4% 3.5%
No of batches 18 24
Mold/machine breakdown 0 10
Unplanned model changeovers 0 4
Plan 15000 8000
material consumption 120000 75000
No of SKUs 9 15
Low 2.8% 4.0%
No of batches 13 20
Mold/machine breakdown 0 10
Unplanned model changeovers 0 4

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4.IMPROVE
4.1 IMPROVED SITUATION
INITIAL CONDITION
2% 1% 1% 0% 0%

3%
3% Considering no
change in rejection
due to rest of the
factors
38%

54%

purging during breaks mold changes as per PPC unplanned changeovers unskilled workers machine breakdown
machine startup mold breakdown material contamination Wrong material mixed

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4.IMPROVE
4.1 IMPROVED SITUATION
2.1% rejection %
as per the new
2021 molds and
SKU numbers

Machine/ Mold
Purging during Mold changeover as Unplanned Mold breakdown +
breaks per PPC changeovers Material
contamination

1.43% 1.18% 0.06% 0.13%

o n
u cti
d
re
%
49
0.73% 1.18% 0.06% 0.13%

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4.IMPROVE
4.2 COST IMPACT

Forecasted Rejection 2021 without improvement 2.8%

Improved Rejection 2021 with improvement 2.1%
Cost Saving 2021 8,000,000 PKR

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ACTION PLAN
TITLE PLANNED ACTUAL
PROJECT DAYS 152 Reduction in Rejection -
PRODUCTION DPT PROJECT START TIME
PROJECT END TIME
01-Mar-2021
31-Jul-2021
01-Mar-2021
Injection Molding
2020

S.N TASK DESCRIPTION Mar-21 Apr-21 May-21 Jun-21 Jul-21

W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4

PLANNED
1 Define Project Charter
ACTUAL
PLANNED
2 Measure Process Mapping
ACTUAL
PLANNED
3 Analyse Baseline Setting
ACTUAL
PLANNED
4 Analyse FMEA
ACTUAL
PLANNED
5 Analyse RCA
ACTUAL
PLANNED
6 Analyse Pareto Analysis + Prioritization
ACTUAL
PLANNED
7 Analyse Bechmarking + Target Setting
ACTUAL
Improvement activities + improvement plan PLANNED
8 Improve
(with and without investment) ACTUAL
PLANNED
9 Control Improved (FMEA + Control Plan)
ACTUAL

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 THANK YOU !!!

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