Process Optimization

Process Optimization
Process selected
Plant

Name of the Leader

Team Members

Date of Start

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Process Optimization

P
Planning
PLANNING
A
ANALYSE
Analyse

I
Improve
IMPROVE

C
Control
CONTROL

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Process Optimization

Phase – 1- Planning

No. Parameter
1 Process selected

2 Part number selected for study

3 Machine selected for study

4 Other similar part numbers

where the optimal setting can be
deployed
5 Responses Description Type of Specification
response
(Var/Att)

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Process Optimization

Phase – 1- Planning
Project Planning
Month Month Month
Phase
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
Plan

Analyze

Improve

Control

Phases Planned Start Planned Actual start Actual Status

date Completion date completion
date date
Plan
Analyze

Improve
Control

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Process Optimization

Phase – 1- Planning

Photograph of the part

Response ( Y )

Response Y = Diameter
Specification : 9.00 mm Minimum.

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Process Optimization

Phase – 1- Planning

Design Parameters identified for Optimization

A–
B–
C–
D–
E–
F–
G–
H–
I–

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Process Optimization

Phase – 1 – Planning

No Parameter ( - Setting ) ( + Setting )

C
D

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Process Optimization

P
Planning
PLANNING
A
ANALYSE
Analyze

I
Improve
IMPROVE

C
Control
CONTROL

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Process Optimization
Phase – 2 – Analyze
Step -1

Test - Setting + Setting

1st Run
2nd Run

3rd Run

Median
Range
D ( Difference Between Two
Medians )
d = Average of Two Ranges
D/d

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Process Optimization
Phase – 2 – Analyze
Step -1

Conclusion:

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Process Optimization
Phase – 2 – Analyze
Step -1

Median(+)

Median(-)
Average of Medians
d
1.45*d
1.45*d (after rounding off to the same
decimal place as data. Always round
off to higher number)
UDL(+) = Median(+) + 1.45*d
LDL(+) = Median(+) – 1.45*d
UDL(-) = Median(-) + 1.45*d
LDL(-) = Median(-) – 1.45*d

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Process Optimization
Phase – 2 – Analyze
Step -2 – Method #1 data collection

Is the
contribution
- Setting + Setting Average UDL (+) LDL(+) UDL (-) LDL(-) Conclusion zero
1st run
2nd run
3rd run

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Process Optimization
Phase – 2 – Analyze
Step -2 – Method #1 data collection

Graph

9.9

9.7

9.5
- S e t t ing

9.3 +
S e t t ing
Ave r a ge
9.1
UDL (+)

8.9 LDL( +)

8.7 UDL (-)

LDL( -)
8.5
1st run 2nd run 3rd run

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Process Optimization
Phase – 2 – Analyze
Step -3 – Factorial analysis

Factorial table
Response Is there any parameter
- - - held at a specific setting
because its contribution
+ - -
is not zero Yes/No
- + -
If yes, what are the
+ + - parameters and what are
- - + the settings
+ - + -
- + + -
+ + +
-
-

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Process Optimization

Phase – 2 – Analyze Step -2 – Method #2 data collection (If number

of parameters are<=3)

Response
- - -
+ - -
- + -
+ + -
- - +
+ - +
- + +
+ + +

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Process Optimization

Phase -2 Analyze – Step # 4 – Factorial plots

Main effects plot

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Process Optimization

Phase -2 Analyze – Step # 4 – Factorial plots

Interactions plot

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Process Optimization

Phase -2 Analyze – Step # 4 – Factorial plots

Coefficients in actual value for making equation

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Process Optimization

Phase -2 Analyze – Step # 5 – Math model

Write the Math model of the process based on the

coefficients

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Process Optimization

Phase -2 Analyze – Step # 6 – Optimization

Objective of Y Higher better/ Lower better / Nominal better

Upper boundary of Y

Lower boundary of Y

Nominal value of Y

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Process Optimization

Phase -2 Analyze – Step # 6 – Optimization

Overlaid Contour plot

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Process Optimization

Phase -2 Analyze – Step # 6 – Optimization

Optimal Settings identified using equation

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Process Optimization

P
Planning
PLANNING
A
ANALYSE
Analyze

I
Improve
IMPROVE

C
Control
CONTROL

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Process Optimization

Phase – 3 - Improve

Validation using B vs C

1 Part number selected for validation

2 Better Condition

Current Condition

3 Sample size 3B,3C

4 Sample type Pieces/Batches

5 Response decided for monitoring .

6 Lot quantity (for batches)

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Process Optimization

Phase – 3 - Improve

Data obtained during validation

Piece / Lot Better ( B ) Current ( C )

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Process Optimization

Phase – 3 - Improve
Analysis - B Vs C

1 Part number selected for

validation
2 Average of B
Average of C
3 D/d ratio

4 Xb – Xc (Amount of
Improvement)
5 Sigma (B)

6 Is Xb-Xc greater than k*Sigma Yes/No

(b)

K = 4.2
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Process Optimization

P
Planning
PLANNING
A
ANALYSE
Analyze

I
Improve
IMPROVE

C
Control
CONTROL

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Process Optimization

Phase – 4 - Control

Work Standard Corrected For Standardization…

ORIGINAL DATE 16-09-2002
WORK STANDARD
REVISION DATE 02.03.06
PROCESS
MODEL PART NAME PART NO DOC .NO MACHINE NAME
NAME NO.

QP-WS-SP-
EMXI STRIKER ASSY DOOR 81350-33010 020 UPSETTING 10 CHOWEL-ASR-150
050(02)

WORKING CONDITION

1 46±5 6 5 6 0 0 46±5 46±5

NUMBER SQUEEZE WELD - I COOL - I SLOPE WELD - II COOL - II WELD - III HOLD

1 0 24 9 0 10 0 0 4.0~5.0 KG/CM2
NUMBER COUNT MAX. CURR CURR - I CURR - II CURR - III COND. DEGREE HIGH AIR PRESSURE

SKETCH
History of Problem
1) UPSETTING CRACK

2) UPSETTING DAMAGE

3) COMPONENTS DAMAGE

4) COMPONENTS RUST

5) UNEVEN WELD

6) COMPONENT BURR

S TIPDRESSING NUT / JOB 7) HOLES OFFSET

E
CRATE T 400 1-S
8)UNEVEN HEIGHT
T
Q / CHK FREQ 2 QTY
TRAY
BIG YELLOW I
N
G 50 200

SELF INSPECTION ( PROCESS CONTROL POINT)

CHECKING
SL.NO. DESCRIPTION CONTROL SPEC FREQUENCY INCHARGE
METHOD
VISUAL DEFECTS
NO RUST & NO CRACK
1 RUST & CRACKS VISUAL ONCE IN 50 NOS OPERATOR
NO BURR
2 BURR IN CORNERS & PIERCING HOLES VISUAL ONCE IN 50 NOS OPERATOR
FREE FROM BEND &
3 BEND & DAMAGE DAMAGE VISUAL ONCE IN 50 NOS OPERATOR
NO SCRATCH
4 HEAVY SCRATCHES VISUAL ONCE IN 50 NOS OPERATOR

NOTE : INSERT TO BE CHANGED, IF BULB DIAMETER OF THE LAST COMPONENT FOUND OUT OF SPEC.
AMENDMENT HISTORY
SI NO REV NO DATE REASON
1 01 30.05.03 DOCUMENT NUMBER ADDED

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