1. Follow-Up Unlocking Slide – Flatness Issue
A brief study was conducted to confirm that the flatness of the
unlocking slide is critical to the success of the chamber line.
The next slides show where the process was and the snap shot
of the issues today in Pareto form. This shows a significant shift
of problems, and highlights potential other areas to explore
The closing slide shows the impact to cost, if all things shown
were to hold true and remain constant.

2. unlocking
slide bent
Missing part
Timing gear
Issue
Idler / Code
gear
poracity
Bent
seperator
Loose
retainer /
gap / cam
Bent
suppport bar
Bent Key
stem
Broken
rotary key
lockout
spring
tension
Total Defects Found 371 343 287 222 86 67 23 42 3 5
0
50
100
150
200
250
300
350
400
AxisTitle
Pareto Chart of Chamber Part Defects
for 9 Weeks
Prior study that drove us to adding
a flattening operation to solve
the problem identified by a bow

3. 0
10
20
30
40
50
60
Timing gear
issue
Bent Key
Stem
Missing parts
-Spring
Idler/code
gear poracity
Bent
separator
Missing parts Unlocking
slide bent
Missing
parts- Detent
Broken
rotary key
Bent support
bar
Lock out
spring
tension
Loose
retainer gap
Unlocking Slide - Confirm Flattening
MAY 13 thru MAY 20 - 2014
This study is a snap shot in which all parts
went through the flattening die

4. ncr count hours
34035 14205 113.6
33837 9256 74
33706 9641 71
258.6
Hours reported 258.6
$ per hour $ 16.75
Cost per NCRs $ 4,331.55
Rejected (scrap) 9000
Part cost 0.52
Potential scrap cost $ 4,680.00
Total Cost since $ 9,011.55
March to date
Some of the rejected parts may yet to salvaged
at second past
chamber line day rate 1,000
cost per unit $ 12.30
days of production 41
revenue $ 504,300.00
5% improvement $ 25,215.00
at assembly
4% improvement $ 20,172.00
at assembly
During a 41 day period data was collected for rework/sort
Assumption was made that this internal rework yielded an
Improvement of 4-5% at the chamber line and then
calculated potential savings based on gross cost.
The result was $10,000 savings if the rework labor was taken into
consideration.
If this problem can be corrected the savings would be estimated
to be at $120,000, based on the information at hand. This does not
take into account the fact the previously 40 chambers a week
were being reworked and to date this condition is all but gone.
Cost Impact to chamber line

5. Summary – Correction by the Supplier
or the option of using a secondary operation
to remove the bow for the part
The tests confirmed that the removing the bow resulted in the predicted
rework reduction and improved first pass yield.
Savings are expected to exceed the original projected savings due to
the change of a single cycle , one part process to a ten parts per cycle
process, making the flattening process faster and more effective