Elimination of Waste and Scrap Cost creating a way forward with the Process Coach and the Team Leader of this area to find the root cause on why these slider doors were being bent.

1. 6-PANEL
STANDARD REPORTING METHOD
FOR PROBLEM SOLVING
Project Leader: Matt Hunt
Process Owner: James Whaley
Project Champion: Bill Hodges
Project Location: Kansas City Integrated Stamping Plant
Project Completion Date: 6/17/2020
M/H Roof Slider Doors Bent Corner Lower Forward

2. 6-PANEL DEFINE VOICE OF THE CUSTOMER
D M A I C R
Team Members:
❑ Todd Zellak – KCISP Production Superintendent
❑ Matthew Hunt – KCISP MPS
❑ James Whaley Production Supervisor
❑ Marty Holstead – Metal Finish
❑ Therese Bayer (KCAP Blackbelt)
❑ Bill Hodges – KCISP Area Manager
❑ Marty Wagner – Maintenance
❑ Myra Taylor - Body

3. 6-PANEL DEFINE VOICE OF THE CUSTOMER
D M A I C R
VOICE OF THE CUSTOMER:
Customer requires Slider Door Sub assemblies that are dimensionally correct.
CTQ/CTF STATEMENT (Critical To Quality/Flow) - Customer Requirement:
KCISP must produce parts that meet the standard panel quality levels.
COST OF POOR QUALITY/FLOW:
40 substandard sliders were produced that required repair on units.
SCOPE AND GOAL:
Reduce nonconforming parts by 100%.
Line: Slider / Barn Sub AssemblyArea: KCISP Sub Assembly
Part/Process Name: Slider Sub Part / Op. Exit Load
Plant: KCISP
PROBLEM STATEMENT
Slider Sub Assemblies were produced
with bent lower forward corner.

4. 6-PANEL D M A I C R
MEASURE
Method (Process)
Environment
Proper
Engineering
level of
parts
Manpower
Material Machine
- PJO process
KPOV and KPIVs – Cause & Effect Diagram
- JSA / OIS
X3
X2
X1
Key Process Input Variables: In Y = f(X)
X1 = Load into rack process
X2 = JSA / OSI PCP / PVS Process – OK to run
X3 = PJO Process
X4 = Load Table Height
X5 = Racks
- Loading into rack process
X4 - Load table height
X5 - Racks

5. 6-PANEL D M A I C R
ANALYZE & IMPROVE
Key Process Input Variable X1 : Load into rack process.
Analysis :
❑ The load process on the Slider
Door consists of:
• Panel travels down rollers and is slid
into the rack.
• Roller height critical to transfer process
Action :
❑ Adjust rollers to optimize load and
accommodate both styles of racks.
O

6. 6-PANEL D M A I C R
ANALYZE & IMPROVE
Key Process Input Variable X2: JSA / OIS
Analysis:
❑ JSA / OIS calls out for operator to
inspect for surface defects along with
screening one door assembly every two
racks for quality assurance.
Results:
❑ Raise awareness of operators to potential failure mode.
❑ Operators directed to perform visual check on corners o
validate load process
Action :
❑ JSA / OIS updated to call out specific
checks for the bent corners.
❑ Visual aid added at load station

7. 6-PANEL ANALYZE & IMPROVE
D M A I C R
Key Process Input Variable X3: PJO Process
Analysis:
❑ PJO performed start of shift on new operators
Results:
❑ Process was followed, however rack variation was an escape
point
❑ Action :
• PJO was performed on new operator

8. 6-PANEL D M A I C R
CONTROL
Key Process Input Variable X4: Load Table Height
Analysis: JSA / OIS
❑ Load table height was low for the newer
style of racks.
Results:
❑ Panels are consistently free of damage to forward
corners.
Action :
❑ Load table height was adjusted to
work with both new and old racks.

9. 6-PANEL D M A I R
REPLICATE
C
Key Process Input Variable X5: Racks
Analysis
❑ 3/2018 new racks delivered to support FCSD requirements
• 60 MH racks
• 15 LR Racks
❑ Plywood lower bed slightly thicker on the newer style of rack
Actions:
❑ No action required, process optimized with roller adjustments
Results:
❑ Panels are loaded without damage to lower forward corner

10. 6-PANEL
OIS/JSA Sheet: Indicates two areas for operator inspection
Visual Aid:
Visual aid focuses on the
transition between the
slider and the racks. The
aid directs the operator to
inspect the rollers if issues
occur with loading the
slider into the rack.

11. 6-PANEL
REPLICATION OPPORTUNITIES
D M A I C R
CONTROL
KCISP Stamping Sub Assembly Areas:
In addition to the slider line, this replication should be introduced in our other
areas that have the same transition of parts from table to rack.
(front door unload, rear cargo door unload)
KCAP Truck Body Sub Assembly Areas:
Similar to the KCISP Stamping Plant Sub Assembly Areas. Truck Body has the
opportunity in their sub assembly areas to replicate the same changes to their
OIS/JSA Sheets and create visual aids to inspect bent corners/roller heights for
transition.