Six-Sigma Panel for Die Set Correction.

1. KCISP
SIX-SIGMA COST PANEL
Location: Press Line #1
Project: Die Set Die Location

2. 6-PANEL DEFINE VOICE OF THE CUSTOMER
D M A I C R
Team Members:
 Todd Beck, Team Leader Press
 Tim Lemka, Team Leader Press
 Andy Gray, Team Leader Press
 James Whaley, Process Coach
 William Spicer, Process Coach
 Roderick Howard, Process Coach
 Ivy Poole and Warren Decker, Die Setters
 Scott Boylan and Randy Gorham, Die Setters
 Dylan Jones and Robert Oates, Die Setters
 Matthew Hunt & Bill Hodges, Project Leader
 Todd Zellak, Project Owner
 Bill Hodges and Todd Zellak, Project Champions
Project Location: Press Line 1 KCISP
Project Completion Date: 1/28/2021
SIX-SIGMA PANEL

3. 6-PANEL
PROBLEM STATEMENT
During the Die Set process dies do not
clamp properly as a result of die
location errors resulting in locating
pins breaking resulting in excessive
DEFINE VOICE OF THE CUSTOMER
D M A I C R
VOICE OF THE CUSTOMER:
Die Sets not clamping properly result in excessive downtime.
CTQ/CTC STATEMENT (Critical To Quality/Cost - Customer Requirement):
Die Set process must be completed in 6 minutes or less to maintain schedule.
COST OF POOR QUALITY/COST:
Extended die set time, process inefficiencies. 3 major occurrences in 2020 resulted in 140 minutes of
downtime and potential to require an extra shift to catch up.
SCOPE AND GOAL:
Reduced die set location issues by 50%.
Plant: KCISP
Line: Stamping Press #1
Area: Stamping Press
Part/Process Name: Die Set Process

4. 6-PANEL DEFINE VOICE OF THE CUSTOMER
D M A I C R
 Process

5. 6-PANEL
Method (Process)
Environment
Reduce die
location related
downtime 50%
Manpower
Material Machine
- Gripper Crane
- Level
OIS Crane
Operator
D M A I C R
MEASURE
 KPOV and KPIVs – Cause & Effect Diagram
- Bolsters
Gripper
Crane
Operators
WDX Locator
Pin System
Standards
X1
Key Process Input Variables: In Y = f(X)
X1 = Revise WDX Standards Die Locating Pin System

6. 6-PANEL DEFINE VOICE OF THE CUSTOMER
D M A I C R
New Design Old Design
 Key Process Input Variable #X1: Die Location Bolster Pin System
Bolster pin
engagement
to 50mm
from 25 mm
increases
robustness
of process

7. 6-PANEL DEFINE VOICE OF THE CUSTOMER
D M A I C R
B1 14 holes
B2 14 Holes
B3 16 holes
B4 14 holes
Bolster holes drilled out and hardened inserts Installed C and D sides
 Key Process Input Variable #X1: Die Location Bolster Pin System

8. 6-PANEL D M A I C R
ANALYZE & IMPROVE
 Key Process Input Variable #X1: Die Location Bolster Pin System
YTD (10/22) 140 minutes
0 die location failures since shutdown work as of 1/21/21.
BEFORE:
AFTER:
17 HEADS $40.50 8 HOURS = $5,508 Per Shift
3 occurrences resulted in Stamping having to run Production on 3 Saturdays to make
up lost time.
TOTAL $16,524

9. 6-PANEL
 Replication: Where else in the Area or Plant can this be
replicated?
D M A I R
REPLICATE
C
 This is a replication project that was developed jointly with Stamping
Engineering, DSP and KSP.
 DSP and KSP have partially implemented.
 KCISP will move forward with P2 as required.

10. 6-PANEL
Appendix

11. 6-PANEL DEFINE VOICE OF THE CUSTOMER
D M A I C R
 Process

12. 6-PANEL DEFINE VOICE OF THE CUSTOMER
D M A I C R

13. 6-PANEL DEFINE VOICE OF THE CUSTOMER
D M A I C R
New Design Old Design
 Key Process Input Variable #X1: Die Location Bolster Pin System

14. 6-PANEL DEFINE VOICE OF THE CUSTOMER
D M A I C R
Bolster Pin New Style Bolster Sleeve Hardened Inserts
Revised Die Location Bolster Pin System
 Key Process Input Variable #X1: Die Location Bolster Pin System
Hardened inserts allow tighter tolerances
and reduce location errors.