Scorpion Motor Noise - JE BB (part)-1

Excellence in motors since 1959 Page : 1
Project Title : Automotive Motor Noise
Prepared By:
Peter Zhou

Define PhaseDefine Phase
Team Charter
Project Leader : Peter Zhou
Name Functional Area Reporting to
1. Paul Tsang HA Q&R xxxx
2. CL Chiang C&S Shaft xxxx
3. JN Ta Corp. Engg xxxx
4. Howard IP Corp. Engg xxxx
5. Peter Lai HA Engg xxxx
6. LapLeong Ma HA Q&R xxxx
7. Pierre Wong JENA xxxx

Problem Statement :
End customer from N.A. complained about NVH issue (i.e. abnormal noise)
by shaft gear mating when installed inside the pump unit. All inventory in
N.A. has been rejected for sorting in China.
For this brand new designed pilot product there was no objective noise
measurement standard developed at both sides for grinding noise inspection at
certain sensitive frequency (e.g. 1K and 2K Hz)
Goal/Objective Statement :
To reduce the current grinding noise defect rate from current 20000 PPM to
5000 PPM with well established shop floor outgoing inspection standard
Projected Business Benefits :
Increased market share with further business business expansion;
Significant savings on both customer field returned/sorting and shop floor
process scrap;
Industry NVH application standard development, etc

Defect DefinitionDefect Definition
Customer Complained Two Typical Defects From Field Application
- Noise Level Too Loud from Specific High Speed Range (i.e. Speed 10)
- Abnormal Grinding Noise From Specified Frequency Bands Defined
as Human Being Comfortable Zone (i.e. 1 KHz and 2 KHz ). A New
Product Characteristic Has Been Developed As “ Sound Quality” For
Measurement
Before the customer complaints there were no specific technical spec. available.
All field rejection was based on customer subjective judgement.

Defect Graphic Demonstration By Sound MeasurementDefect Graphic Demonstration By Sound Measurement

Practical Problem Statement:
Customer CTQ (Y): Sound Quality of Gear Mating
Measurable y’s: Noise dBA Level and Sound Quality Index
Continuous or Attribute y? Continuous
Unit: dBA
Sound Quality
Defect: 20000 PPM
Customer Specification: To Be Developed By the Team

Define Phase
Process Trend Chart - BaselineProcess Trend Chart - Baseline
20000
0
5000
10000
15000
20000
25000
30000
Nov Jan Mar Apr May June July
MeasureMeasure AnalyzeAnalyze ImproveImprove ControlControl RealizationRealization
BASELINEBASELINE
GOALGOAL

Rating of
Importance to
Customer
7 9 8 9 9 7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
MotorTotal
Length
MotorShaftT.I.R.
Input/Output
Balancing
MotorGrinding
Noise
MotorVibration
Ass'yMotorShaft
Concentricity
Total
Process Step Process Input
1
Lamination
Height
9 0 0 0 0 0 63
2 Shaft Burrs 0 0 0 9 0 0 81
3
Shaft Teeth
T.I.R.
0 0 7 3 0 90
4
Shaft Teeth
Crowning Value 0 0 0 9 0 0 81
5 Shaft T.I.R. 0 3 3 3 7 127
6
Input Bracket
Concentricity
0 0 0 0 1 7 58
7
Output Bracket
Concentricity
0 0 0 0 1 7 58
8
Input Bearing
Concentricity
0 0 0 0 1 5 44
9
Output Bearing
Concentricity
0 0 0 0 1 5 44
10
Product
Balancing Spec 0 0 9 0 1 0 81
11
Lam. Screw
Hole
Concentricity
0 0 0 0 0 9 63
12 0
13 0
14 0
15 0
16 0
17 0
18 0
19 0
20 0
0
Total
63
0
96
252
99
280
0
0
0
0
0
0
0
0
0
Lower Spec
Target
Upper Spec
Cause and Effect
Matrix
This table provides the initial input to the FMEA. When each of the output variables (requirements) are
not correct, that represents potential "EFFECTS". When each input variable is not correct, that
represents "Failure Modes".
Measure PhaseMeasure Phase

Sub-Assembly ComponentsSub-Assembly Components
Process Capability MeasurementProcess Capability Measurement

Customer Requirement
(Output Variable)
Measurement Technique
%R&R or P/T
Ratio
Upper
Spec
Limit
Target
Lower
Spec
Limit
Cp Cpk
Sample
Size
Date Actions
Shaft Crowning Shaft Teeth Mahr Mchine 77% 7.5 5 0 * -1.34 150 Nov-03
Need to Train Operator for Correct
Measurement Method
Shaft T.I.R. T.I.R. Indicator 52.88% 0.05 0.025 0 0.8 0.77 37 Nov-03
Need to Change the Measurement
Gate Immediately
Input Balancing Input Balancing Meter 8.90% 800 400 0 0.91 0.72 32 Nov-03 Good Gage
Output Balancing Balancing Meter 9.27% 800 400 0 1 0.7 32 Nov-03 Good Gage
Output Hub T.I.R. Hub T.I.R. Indicator 6.09% 0.1 0.05 0 1.17 0.92 31 Nov-03 Good Gage
Key Process Output Variable
Capability Status Sheet

-6 -4 -2 0 2 4 6 8 10
LSL USL
Process Capability Analysis For Shaft eeth Crowning Value
USL
Target
LSL
Mean
Sample N
StDev (Within)
StDev (Overall)
Z.Bench
Z.USL
Z.LSL
Cpk
Cpm
Z.Bench
Z.USL
Z.LSL
Ppk
PPM< LSL
PPM> USL
PPMTotal
PPM< LSL
PPM> USL
PPMTotal
PPM < LSL
PPM > USL
PPM Total
10.0000
*
5.0000
-1.3379
150
1.57087
1.64989
-4.03
7.22
-4.03
-1.34
*
-3.84
6.87
-3.84
-1.28
1000000.00
0.00
1000000.00
999972.66
0.00
999972.66
999938.84
0.00
999938.84
Process Data
Potential (Within) Capability
Overall Capability Observed Performance Exp. "Within" Performance Exp. "Overall" Performance
Within
Overall
2.00.5-1.0-2.5-4.0-5.5
95% Confidence Interval for Mu
-1.05-1.15-1.25-1.35-1.45-1.55-1.65-1.75
95% Confidence Interval for Median
Variable: History
-1.70000
1.47945
-1.60368
Maximum
3rd Quartile
Median
1st Quartile
Minimum
N
Kurtosis
Skewness
Variance
StDev
Mean
P-Value:
A-Squared:
-1.10000
1.85800
-1.07218
1.90000
0.00000
-1.40000
-2.50000
-6.10000
150
-3.6E-01
-1.3E-01
2.71302
1.64713
-1.33793
0.303
0.431
95% Confidence Interval for Sigma
Anderson-Darling Normality Test
Descriptive Statistics
Incoming Shaft Crowning Value CapabilityIncoming Shaft Crowning Value Capability

0.0450.0350.0250.0150.005
0.0300.0250.020
Bare Shaft TIR
2.00E-02
8.70E-03
2.23E-02
Maximum
3rd Quartile
Median
1st Quartile
Minimum
N
Kurtosis
Skewness
Variance
StDev
Mean
P-Value:
A-Squared:
3.00E-02
1.39E-02
2.94E-02
5.00E-02
3.40E-02
2.50E-02
1.80E-02
5.00E-03
37
-4.7E-01
0.235228
1.14E-04
1.07E-02
2.58E-02
0.540
0.310
0.060.050.040.030.020.010.00-0.01
USLLSL
Process Capability Analysis for Bare Shaft TIR
PPMTotal
PPM> USL
PPM< LSL
PPMTotal
PPM> USL
PPM< LSL
PPMTotal
PPM> USL
PPM< LSL
Ppk
PPL
PPU
Pp
Cpm
Cpk
CPL
CPU
Cp
StDev (Overall)
StDev (Within)
Sample N
Mean
LSL
Target
USL
20695.95
12458.49
8237.47
17111.91
10395.49
6716.43
0.00
0.00
0.00
0.75
0.80
0.75
0.77
*
0.77
0.82
0.77
0.80
0.0107738
0.0104519
37
0.0258378
0.0000000
*
0.0500000
Exp. "Overall" PerformanceExp. "Within" PerformanceObserved PerformanceOverall Capability
Process Data
Within
Overall
Incoming Shaft T.I.R. CapabilityIncoming Shaft T.I.R. Capability

Misc:
Tolerance:
Reported by:
Date of study:
Gage name:
0
13
12
11
21
Xbar Chart by OP
SampleMean
Mean=11.60
UCL=11.92
LCL=11.28
0
1.5
1.0
0.5
0.0
21
R Chart by OP
SampleRange
R=0.315
UCL=0.8109
LCL=0
10987654321
12.8
11.8
10.8
Part_No
OP
OP*Part_No Interaction
Average
1
2
21
13
12
11
10
OP
By OP
10987654321
13
12
11
10
Part_No
By Part_No
%Contribution
%StudyVar
Part-to-PartReprodRepeatGage R&R
100
50
0
Components of Variation
Percent
Gage R&R (ANOVA) for Shaft Teeth Mahr M/C
Two-Way ANOVA Table With Interaction
Source DF SS MS F P
Part_No 9 11.5875 1.2875 5.1344 0.01148
OP 1 11.5282 11.5282 45.9730 0.00008
OP*Part_No 9 2.2568 0.2508 5.1881 0.00011
Repeatability 40 1.9333 0.0483
Total 59 27.3058
Shaft Teeth CH Value Gage R&R
%Contribution
Source VarComp (of VarComp)
Total Gage R&R 0.49172 74.00
Repeatability 0.04833 7.27
Reproducibility 0.44339 66.72
OP 0.37591 56.57
OP*Part_No 0.06748 10.15
Part-To-Part 0.17279 26.00
Total Variation 0.66451 100.00
StdDev Study Var %Study Var %Tolerance
Source (SD) (5.15*SD) (%SV) (SV/Toler)
Total Gage R&R 0.701229 3.61133 86.02 72.23
Repeatability 0.219848 1.13222 26.97 22.64
Reproducibility 0.665875 3.42925 81.68 68.59
OP 0.613118 3.15756 75.21 63.15
OP*Part_No 0.259760 1.33776 31.87 26.76
Part-To-Part 0.415680 2.14075 50.99 42.82
Total Variation 0.815176 4.19816 100.00 83.96
Number of Distinct Categories = 1
GR&R Study For Shaft Teeth CH Mahr M/CGR&R Study For Shaft Teeth CH Mahr M/C
Operator w/ incorrect
Measure Method

In-Process Assembly DataIn-Process Assembly Data

800700600500400300200
550500450400
Balancing Input
399.463
114.947
430.791
Maximum
3rd Quartile
Median
1st Quartile
Minimum
N
Kurtosis
Skewness
Variance
StDev
Mean
P-Value:
A-Squared:
540.537
190.619
534.178
799.000
581.625
481.750
376.000
211.500
32
-1.8E-01
0.364069
20557.4
143.379
482.484
0.662
0.268
10008006004002000
USLLSL
Process Capability Analysis for Balancing Input
PPM Total
PPM > USL
PPM < LSL
PPM Total
PPM > USL
PPM < LSL
PPM Total
PPM > USL
PPM < LSL
Ppk
PPL
PPU
Pp
Cpm
Cpk
CPL
CPU
Cp
StDev (Overall)
StDev (Within)
Sample N
Mean
LSL
Target
USL
14441.18
14019.40
421.79
15805.53
15297.00
508.52
0.00
0.00
0.00
0.73
1.11
0.73
0.92
*
0.72
1.10
0.72
0.91
144.539
146.841
32
482.484
0.000
*
800.000
Exp. "Overall" PerformanceExp. "Within" PerformanceObserved PerformanceOverall Capability
Process Data
Within
Overall
Input Balancing Process CapabilityInput Balancing Process Capability

Misc:
Tolerance:
Reported by:
Date of study:
Gage name:
0
35.3
35.2
35.1
35.0
34.9
34.8
BA
Xbar Chart by Operator
SampleMean
Mean=35.00
UCL=35.04
LCL=34.96
0
0.10
0.05
0.00
BA
R Chart by Operator
SampleRange
R=0.021
UCL=0.06861
LCL=0
10987654321
35.2
35.1
35.0
34.9
34.8
Serial
Operator
Operator*Serial Interaction
Average
A
B
BA
35.3
35.2
35.1
35.0
34.9
34.8
Operator
By Operator
10987654321
35.3
35.2
35.1
35.0
34.9
34.8
Serial
By Serial
%Contribution
%StudyVar
%Tolerance
140
120
100
80
60
40
20
0
Percent
Gage R&R (ANOVA) for Stator Lam. Height Two-Way ANOVA Table With Interaction
Source DF SS MS F P
Serial 9 0.65816 0.0731289 127.550 0.00000
Operator 1 0.00169 0.0016900 2.948 0.12013
Operator*Serial 9 0.00516 0.0005733 1.318 0.28850
Repeatability 20 0.00870 0.0004350
Total 39 0.67371
U9845 Stator Lamination Heigt Gage R&R
%Contribution
Total Gage R&R 0.000539 2.88
Repeatability 0.000478 2.56
Reproducibility 0.000061 0.32
Operator 0.000061 0.32
Part-To-Part 0.018163 97.12
Total Variation 0.018701 100.00
Total Gage R&R 0.023206 0.119513 16.97 23.90
Repeatability 0.021862 0.112587 15.99 22.52
Reproducibility 0.007785 0.040092 5.69 8.02
Operator 0.007785 0.040092 5.69 8.02
Part-To-Part 0.134769 0.694061 98.55 138.81
Total Variation 0.136753 0.704276 100.00 140.86
GR&R Study For Lamination Height CaliperGR&R Study For Lamination Height Caliper
Good
Gage

Misc:
Tolerance:
Reported by:
Date of study:
Gage name:
0
0.06
0.05
0.04
0.03
0.02
BA
Xbar Chart by Operator
SampleMean
Mean=0.04025
UCL=0.04307
LCL=0.03743
0
0.010
0.005
0.000
BA
R Chart by Operator
SampleRange
R=0.0015
UCL=0.004901
LCL=0
10987654321
0.06
0.05
0.04
0.03
0.02
Serial
Operator
Operator*Serial Interaction
Average
A
B
BA
0.06
0.05
0.04
0.03
0.02
Operator
By Operator
10987654321
0.06
0.05
0.04
0.03
0.02
Serial
By Serial
%Contribution
%StudyVar
%Tolerance
100
50
0
Percent
Gage R&R (ANOVA) for Output Bracket Hub (T.I.R) Two-Way ANOVA Table With Interaction
Source DF SS MS F P
Serial 9 0.0075725 0.0008414 43.8986 0.00000
Operator 1 0.0000025 0.0000025 0.1304 0.72631
Operator*Serial 9 0.0001725 0.0000192 2.5556 0.03864
Repeatability 20 0.0001500 0.0000075
Total 39 0.0078975
Output Bracket Hub T.I.R. Gage R&R
%Contribution
Total Gage R&R 1.33E-05 6.09
Repeatability 7.50E-06 3.43
Reproducibility 5.83E-06 2.66
Operator 0.00E+00 0.00
Operator*Serial 5.83E-06 2.66
Part-To-Part 2.06E-04 93.91
Total Variation 2.19E-04 100.00
Total Gage R&R 3.65E-03 1.88E-02 24.68 18.81
Repeatability 2.74E-03 1.41E-02 18.51 14.10
Reproducibility 2.42E-03 1.24E-02 16.32 12.44
Operator 0.00E+00 0.00E+00 0.00 0.00
Operator*Serial 2.42E-03 1.24E-02 16.32 12.44
Part-To-Part 1.43E-02 7.38E-02 96.91 73.84
Total Variation 1.48E-02 7.62E-02 100.00 76.19
GR&R Study For Output Hub T.I.R. IndicatorGR&R Study For Output Hub T.I.R. Indicator
Good
Gage

Measurement Device : BK 4188 Sound Meter
w/ Microphone
Acoustic Room : 40 dBA Environment Chamber
Installation Distance : 26.5 cm Above the Part
PC Software : B&K Sound Quality 7698 System
Sound Frequency : 1000 Hz
2000 Hz
Sound Level MeasurementSound Level Measurement
Measured Sound Level (dBA) Will Be Transformed Into
Discrete Data In the Specified Frequency, Which Will Be
Added Up Together as the Sound Quality Index.

Speed 10
Frequency
949290888684
3.0
2.5
2.0
1.5
1.0
0.5
0.0
Mean 88.89
StDev2.793
N 16
Histogram (with Normal Curve) of Speed 10
Speed10
95.0
92.5
90.0
87.5
85.0
Boxplot of Speed 10
Descriptive Statistics: dba-10
Variable N N* Mean SE Mean StDev Minimum Q1 Median Q3
dba-10 32 0 88.856 0.535 3.024 84.800 86.100 88.400 90.800
Variable Maximum
dba-10 95.000
Sound Level Data at High Speed 10Sound Level Data at High Speed 10
No Customer Spec.
Available Now!

b. Abnormal Noise Defect From Shop floor Per Subjective Standardb. Abnormal Noise Defect From Shop floor Per Subjective Standard
Sound Quality Index Will be Referred If There Was Any ConfusionSound Quality Index Will be Referred If There Was Any Confusion
DPMO Z-Score Cpk Sigma Level
14000 2.20 0.73 3.7

QFD - Noise (1)QFD - Noise (1)
StackingPosition
LaminationHeight
FittingDimension
Angle
WireTension
SpindleSpeed
TricklingAmount
TricklingTime
SurfaceFinishing
Roundness
T.I.R.
BalancingInput
CuttingDepth
CuttingLength
InputT.I.R.
Laminationheight
SurfaceLeveling
ScrewID
WireTension
SpindleSpeed
CoilHeight
Pressure
Push-offForce
Concentricity
Pressure
Push-offForce
Concentricity
Shaft Diameter, Crowning value, T.I.R.,Knurling Height, Roundness5
Magnet wire Diameter, Coating 2
Commutator Roundness, Bar-to-bar, Surface finishing 3
Cooling fan ID, Roundness 2
Lamination Height, Surface Finishing, Resistance 3
Magnet wire Diameter, Tension Strength, Coating 2
Lamination Height, Surface Finishing, Resistance
4
Carbon brush Hardness, Resistance 2
Ball bearing -input ID, OD, Roundness, Oil Content 3
Ball bearing - output ID, OD, Roundness, Oil Content 3
Bracket-input ID, OD, Surface Finishing, Roundness, Eccentric, Height5
Bracket -output ID, OD, Surface Finishing, Roundness, Eccentric, Height5
57.8+0.2/-0mm
34.5+0/-0.5mm
24.9+/-0.1mm
7.5+/-0.2deg
1000~1200g
4.6~5.6mleach
95-96/110-111sec
3.5-5.5um
3.0ummax
0.01mmMax
1.8mmMax
20mmMax
0.01mmMax
35.0+/-0.25mm
0.20Max
3000g
17.5mmMax
700-3000
20kgMin
60kgMin
72 27 72 72 18 18 36 36 27 27 42 9 27 27 24 36 36 36 12 12 27 12 141 12 141
Matrix
Strong
Medium
Weak
Weight
9
3
1
Process Capability
How Importance
Armature Ass'y
CoilWinding
Stator Ass'y
StatorWelding
Part Characteristic Values
Process Parameters (Hows)
Bracket Ass'y
Importance
Stacking
CommutatorFitting
CoilWinding
Trickling
Comm.Turning
ArmatureBalancing
InputBracket
FittingBearing
Process Parameter Values
RotorStatorBracket
Part Characteristics (Whats)
OnputBracket
FittingBearing
1st Priority -
Bracket Ass’y
Analyze PhaseAnalyze Phase

QualityControl
Maintenance
MistakeProofing
Training
Stacking Position 2 2 2 2 1 16
Lamination Height 3 1 1 2 1 6
Fitting Dimension 3 3 2 3 2 108
Angle 3 2 1 3 2 36
Wire Tension 4 3 3 2 2 144
Spindle Speed 2 2 2 1 1 8
Trickling Amount 4 3 3 5 2 360
Trickling Time 4 1 2 4 2 64
Surface Finishing 3 1 1 3 2 18
Roundness 3 3 2 3 2 108
T.I.R. 3 2 1 3 2 36
Balancing Input 5 1 1 4 1 20
Cutting Depth 4 1 1 3 2 24
Cutting Length 4 1 1 3 2 24
Input T.I.R. 4 3 2 3 1 72
Lamination height 3 2 2 2 1 24
Surface Leveling 3 2 1 2 1 12
Screw ID 4 3 3 3 3 324
Wire Tension 4 3 3 2 2 144
Spindle Speed 2 2 2 1 1 8
Coil Height 3 2 2 2 1 24
Pressure 3 2 1 2 1 12
Push-off Force 3 2 1 2 1 12
Concentricity 4 3 2 3 3 216
Pressure 3 2 1 2 1 12
Concentricity 4 3 2 3 3 216
Fitting Armature To
Output Bracket
Shaft Turning Freedom 4 3 3 3 2 216
Screw Fastening 3 2 2 3 1 36
Shaft Output T.I.R 4 3 3 3 2 216
Fitting Carbon Brush 0
Dimension 3 2 2 2 1 24
FinalAss'y
Final Ass'y
Cooling Fan Fitting
ArmatureAss'y
Stacking
Commutator Fitting
Coil Winding
Trickling
Comm. Turning
Armature Balancing
StatorAss'y
Stator Welding
Coil Winding
BracketAss'y
Input Bracket
Fitting Bearing
Onput Bracket
Fitting Bearing
Remark
Planning Requirement
Severity
Difficulty
Frequency
Process Parameters
(WHAT)
Production
Requirement (HOWS)
AbilitytoDetect
TotalPoint
Process Parameter Values
Importance
ProcessCapability
QFD - Noise (2)QFD - Noise (2)
1st Priority to
Monitor Noise

Pareto Analysis Of QFD Process PlanningPareto Analysis Of QFD Process Planning
0
50
100
150
200
250
S
haftO
utputT.I.R
S
haftTurning
Freedom
C
oncentricity
(InputB
racket)
Concentricity(O
utputB
racket)
Stacking
P
osition
Fitting
D
im
ension
Angle
C
om
m
.T.I.R.

Item# Process / Product Parameter
Keyprocess Inputs
Variables
[KPIVs](X's)
KeyProcess
OutputsVariables
[KPOVs} (Y's)
Levels of
Interest (for
each input)
[Process Limit]
Specification (for
each input)
Appropriate
Test(s) /
Analysis
Is Input
Vital
(Yes/No)?
Comments
1 Armature Stacking
Gear Teeth
Crowning
Abnormal Noise
(dBA/Sound
Quality)
Positive and
Negative
>5 Multi-Vari Yes
Samples
from one
shift
2 Armature Balancing Input Balancing
Abnormal Noise
(dBA/Sound
Quality)
200 - 1200
mg.cm
500 mg.cm Multi-Vari Yes
Samples
from one
shift
3 Armature Balancing Output Balancing
Abnormal Noise
(dBA/Sound
Quality)
200 - 1200
mg.cm
500 mg.cm Multi-Vari Yes
Samples
from one
shift
4 Fitting Armature Into Bracket Bracket Shaft TIR
Abnormal Noise
(dBA/Sound
Quality)
0.010 - 0.018
mm
Nil T-Test No
Samples
from one
shift
KPIV Matrix

67.5 68.5 69.5 70.5 71.5 72.5 73.5
67.8 68.3 68.8 69.3
Variable: dB
A-Squared:
P-Value:
Mean
StDev
Variance
Skewness
Kurtosis
N
Minimum
1st Quartile
Median
3rd Quartile
Maximum
67.7576
0.4020
67.7714
0.271
0.529
68.4333
0.6439
0.414667
0.436417
-1.63033
6
67.7000
67.8500
68.3000
69.1500
69.3000
69.1091
1.5794
69.2286
TIR: 0.004
67.5 68.5 69.5 70.5 71.5 72.5 73.5
67 68 69 70 71 72 73 74
Variable: dB
A-Squared:
P-Value:
Mean
StDev
Variance
Skewness
Kurtosis
N
Minimum
1st Quartile
Median
3rd Quartile
Maximum
66.8151
1.5271
67.6000
0.405
0.206
69.9800
2.5489
6.497
0.626605
-2.47711
5
67.6000
67.9000
68.7000
72.7000
73.3000
73.1449
7.3245
73.3000
TIR: 0.006
67.5 68.5 69.5 70.5 71.5 72.5 73.5
67.5 68.5 69.5 70.5 71.5 72.5
Variable: dB
A-Squared:
P-Value:
Mean
StDev
Variance
Skewness
Kurtosis
N
Minimum
1st Quartile
Median
3rd Quartile
Maximum
68.0654
0.9817
67.9000
0.142
0.923
70.1000
1.6386
2.685
-1.5E-01
-3.8E-01
5
67.9000
68.5500
70.3000
71.5500
72.2000
72.1346
4.7086
72.2000
TIR: 0.002
0 1 2 3 4 5 6 7 8 9 10
95% Confidence Intervals for Sigmas
Bartlett's Test
Test Statistic: 6.505
P-Value : 0.039
Levene's Test
P-Value : 0.208
Factor Levels
0.002
0.004
0.006
Test for Equal Variances for dB
Kruskal - Wallis Test For Shaft T.I.R. - (1)Kruskal - Wallis Test For Shaft T.I.R. - (1)

Kruskal-Wallis Test: dB versus TIR
Kruskal-Wallis Test on dB
TIR N Median Ave Rank Z
0.002 5 70.30 10.7 1.25
0.004 6 68.30 6.3 -1.41
0.006 5 68.70 8.9 0.23
Overall 16 8.5
H = 2.35 DF = 2 P = 0.310
H = 2.35 DF = 2 P = 0.308 (adjusted for ties)
P-Value: 0.889
A-Squared: 0.186
N: 16
StDev: 1.60834
Average: -0.0000000
3210-1-2
.999
.99
.95
.80
.50
.20
.05
.01
.001
Probability
RESI1
Normal Probability Plot
Shaft T.I.R.
is Not
KPIV
Kruskal - Wallis Test For Shaft T.I.R. - (2)Kruskal - Wallis Test For Shaft T.I.R. - (2)

2000500
2000
500
2000
500
79
78
77
76
75
74
73
72
output balancing
S1_dBA
5
-1
Multi-Vari Chart for Speed 1dBA by crowning/output/input balancing
input balancing
value
crowning
2000500
2000
500
2000
500
83.5
82.5
81.5
80.5
79.5
output balan
S5_dBA
5
-1
Multi-Vari Chart for S5_dBA by crowning/output/input balancing
input balanc
value
crowning
2000500
2000
500
2000
500
91.8
90.8
89.8
88.8
87.8
86.8
85.8
output balan
S10_dBA
5
-1
Multi-Vari Chart for S10_dBA by crowning/output/input balancing
input balanc
value
crowning
Ch/Input/Output
are KPIVs
for dBA
Multi-Vari Study for KPIV - dBAMulti-Vari Study for KPIV - dBA

2000500
2000
500
2000
500
41
36
31
output balancing
S1_loud
5
-1
Multi-Vari Chart for S1_loud by crowning/output/input balancing
input balancing
value
crowning
2000500
2000
500
2000
500
60
55
50
output balancing
S5_loud
5
-1
input balancing
value
crowning
2000500
2000
500
2000
500
90
80
70
output balancing
S10_loud
5
-1
input balancing
value
crowning
Ch/Input/Output
are KPIVs
for Loudness
Multi-Vari Study for KPIV - Sound LoudnessMulti-Vari Study for KPIV - Sound Loudness

Two-Sample T-Test and CI: S1_dBA, Shaft TIR
Two-sample T for S1_dBA
Shaft TI N Mean StDev SE Mean
a 8 75.34 2.63 0.93
b 8 75.86 3.81 1.3
Difference = mu (a) - mu (b)
Estimate for difference: -0.52
95% CI for difference: (-4.03, 2.98)
T-Test of difference = 0 (vs not =): T-Value = -0.32
P-Value = 0.753 DF = 14
Both use Pooled StDev = 3.27
1 2 3 4 5 6 7 8 9
95% Confidence Intervals for Sigmas
b
a
70 75 80
Boxplots of Raw Data
S1_dBA
F-Test
P-Value : 0.351
Levene's Test
P-Value : 0.240
Factor Levels
a
b
Test for Equal Variances for S1_dBA
a b
70
75
80
Shaft TIR
S1_dBA
Boxplots of S1_dBA by Shaft TI
(means are indicated by solid circles)
70 72 74 76 78 80 82
73 74 75 76 77 78
Variable: S1_dBA
A-Squared:
P-Value:
Mean
StDev
Variance
Skewness
Kurtosis
N
Minimum
1st Quartile
Median
3rd Quartile
Maximum
73.1374
1.7400
73.5455
0.358
0.355
75.3375
2.6316
6.92554
0.471267
0.568964
8
71.3000
73.9000
74.9500
77.4000
79.9000
77.5376
5.3561
78.2158
Shaft TIR: a
a=0.010
b=0.018
Shaft T.I.R.
is Not
KPIV
Two Sample T-test For Shaft T.I.R.Two Sample T-test For Shaft T.I.R.

Improve PhaseImprove Phase
Problem Statement:Problem Statement:
To optimize assembly process setting with minimum sound level (dBA) andTo optimize assembly process setting with minimum sound level (dBA) and
sound quality indexsound quality index
Objective:Objective:
2233
full factorial design to optimize the sound level and sound quality indexfull factorial design to optimize the sound level and sound quality index
Study Factor:Study Factor:
A Shaft teeth crowning value (Lo: -1, Hi: +5)A Shaft teeth crowning value (Lo: -1, Hi: +5)
B Armature input balancing (Lo: 500, Hi: 2000)B Armature input balancing (Lo: 500, Hi: 2000)
C Motor output balancing (Lo: 500, Hi: 2000)C Motor output balancing (Lo: 500, Hi: 2000)
Response Interest:Response Interest:
1) Sound level (dBA)1) Sound level (dBA)
2) Sound Quality Index2) Sound Quality Index

Scorpion Motor Speed Range:Scorpion Motor Speed Range:
a.a. Speed 10 - High SpeedSpeed 10 - High Speed (Sound Level & Sound Quality)(Sound Level & Sound Quality)
b.b. Speed 5 - Medium SpeedSpeed 5 - Medium Speed (Sound Quality Only)(Sound Quality Only)
c.c. Speed 1 - Low SpeedSpeed 1 - Low Speed (Sound Quality Only)(Sound Quality Only)
All the three speeds are interested in this DOE study,All the three speeds are interested in this DOE study,
Which means the process optimization should resolveWhich means the process optimization should resolve
all three speeds abnormal noise issue.all three speeds abnormal noise issue.

cr owni ng
val ue
i nput
bal anci ng
out put
bal anci ng
Speed 10
- 1 500 500 94. 6
5 500 500 88. 3
5 500 2000 93. 8
- 1 2000 500 87
- 1 500 500 88. 6
5 2000 500 85. 9
5 2000 2000 85. 3
5 2000 2000 86. 9
- 1 2000 2000 86. 7
- 1 500 2000 88
- 1 2000 2000 88. 8
- 1 2000 500 92
5 2000 500 85. 9
5 500 2000 89. 2
5 500 500 90. 2
- 1 500 2000 91
cr owni ng
val ue
i nput
bal anci ng
out put
bal anci ng
Speed 1 Speed 5 Speed 10
- 1 500 500 40. 5 51 82. 1
5 500 500 30. 9 50. 8 70. 2
5 500 2000 41. 6 68. 3 97. 9
- 1 2000 500 34. 9 51. 8 71. 7
- 1 500 500 31. 3 51. 1 71
5 2000 500 29. 4 48. 8 63. 7
5 2000 2000 29. 9 50. 6 68. 2
5 2000 2000 32. 5 49. 7 68. 8
- 1 2000 2000 44. 3 57. 9 67. 9
- 1 500 2000 43. 6 56. 2 68. 9
- 1 2000 2000 36. 3 55 67
- 1 2000 500 34. 2 49. 1 75. 9
5 2000 500 32. 3 44. 7 65. 4
5 500 2000 36 51. 6 79. 7
5 500 500 36. 9 56. 6 82. 6
- 1 500 2000 38. 8 57. 1 85. 5
Sound Level (dBA)Sound Level (dBA) Sound QualitySound Quality

Speed 10Speed 10 – High Speed Sound Level (dBA)– High Speed Sound Level (dBA)

0.0 0.5 1.0 1.5 2.0 2.5
C
BC
ABC
AB
A
AC
B
Pareto Chart of the Standardized Effects
(response is Speed 10, Alpha = .05)
A: crowning
B: input ba
C: output b
-2 -1 0 1
-1.5
-1.0
-0.5
0.0
0.5
1.0
1.5
Standardized Effect
NormalScore
B
Normal Probability Plot of the Standardized Effects
A: crowning
B: input ba
C: output b
DOE Study On Sound Level dBADOE Study On Sound Level dBA

crowning val input balanc output balan
-1 5 500
2000
500
2000
87.4
88.2
89.0
89.8
90.6
Speed10
Main Effects Plot Speed 10 dBA Means
500 2000
500 2000
86
88
90
86
88
90crowning val
input balanc
output balan
-1
5
500
2000
Interaction Plot For Speed 10 dBA

543210-1-2-3-4-5
3
2
1
0
Residual
Frequency
Histogram of Residuals
151050
8
6
4
2
0
-2
-4
-6
-8
Observation Number
Residual
I Chart of Residuals
Mean=-3.6E-15
UCL=6.755
LCL=-6.755
9190898887
5
0
-5
Fit
Residual
Residuals vs. Fits
210-1-2
5
0
-5
Normal Plot of Residuals
Normal Score
Residual
Residual Plot For dBA Mean

Hi
Lo1.0000
D
New
Cur
d = 1.0000
Minimum
Speed 10
y = 85.90
500.0
2000.0
500.0
2000.0
-1.0
5.0
input ba output bcrowning
[5.0000] [2000.0] [500.0]
Sound Level (dBA) Control OptimizationSound Level (dBA) Control Optimization
Input Balance
Plays Dominant
to Reduce dBA

86.10
85.90
91.50
89.25
87.75
89.50
89.50
91.60
output balan
input balanc
crowning val
5-1
2000
500
2000
500
Cube Plot for Speed 10 dBA
The optimal set-up for a minimum sound level (dBA) should be:
Crowning value - 5, input balancing - 2000, output balancing - 500

Speed 1– Low Speed Sound QualitySpeed 1– Low Speed Sound Quality

210
A
C
B
AB
AC
ABC
BC
A: crowning
B: input ba
C: output b
210-1-2
1.5
1.0
0.5
0.0
-0.5
-1.0
-1.5
Standardized Effect
NormalScore
A
C
A: crowning
B: input ba
C: output b
DOE Study On Sound Quality - Speed 1DOE Study On Sound Quality - Speed 1

output balaninput balanccrowning val
2000
500
2000
500
5-1
38
37
36
35
34
Speed1
Main Effects Plot for Speed1 Sound Quality
2000
500
2000
500
41
36
31
41
36
31
crowning val
input balanc
output balan
2000
500
5
-1
Interaction Plot for Speed1 Sound Quality

-6 -4 -2 0 2 4 6
0
1
2
3
4
Residual
Frequency
Histogram of Residuals
0 5 10 15
-10
0
10
Observation Number
Residual
I Chart of Residuals
Mean=-3.8E-15
UCL=11.12
LCL=-11.12
31 32 33 34 35 36 37 38 39 40
-5
0
5
Fit
Residual
Residuals vs. Fits
-2 -1 0 1 2
-5
0
5
Normal Plot of Residuals
Normal Score
Residual
Residual Plot For Sound Quality Mean

78.95
76.30
72.30
72.05
75.00
78.20
75.05
76.95
-1 5
crowning val
input balanc
output balan
500
2000
500
2000
Cube Plot (data means) for Speed 1
The optimal set-up for a minimum sound quality should be:

Speed 5– Medium Speed Sound QualitySpeed 5– Medium Speed Sound Quality

210
C
B
AB
A
ABC
BC
AC
A: crowning
B: input ba
C: output b
2.52.01.51.00.50.0-0.5-1.0-1.5-2.0
1.5
1.0
0.5
0.0
-0.5
-1.0
-1.5
Standardized Effect
NormalScore
B
C
A: crowning
B: input ba
C: output b

output balaninput balanccrowning val
2000
500
2000
500
5-1
55.8
54.6
53.4
52.2
51.0
Speed5
Main Effects Plot for Speed 5 Sound Quality Mean 2000
500
2000
500
58
53
48
58
53
48
crowning val
input balanc
output balan
2000
500
5
-1
Interaction Plot for Speed5 Sound Quality Mean

2000
500
2000
500
5-1
output balancing
input balancing
crowning value
68.50
88.8077.20
67.45
64.55
76.4076.55
73.80
Cube Plot (data means) for Speed 10
The optimal set-up for a minimum sound quality should be:

31.20
30.85
38.80
33.90
40.30
34.55
41.20
35.90
output balan
input balanc
crowning val
5-1
2000
500
2000
500
Cube Plot for Speed1 Sound Quality Mean
50.15
46.75
59.95
53.70
56.45
50.45
56.65
51.05
output balan
input balanc
crowning val
5-1
2000
500
2000
500
Cube Plot for Speed5 Sound Quality Mean
68.50
64.55
88.80
76.40
67.45
73.80
77.20
76.55
output balan
input balanc
crowning val
5-1
2000
500
2000
500
Cube Plot for Speed10 Sound Quality Index
The Optimal Process Set-up In Each Speed is :
Crowning value - 5,
Input balancing - 2000,
Output balancing - 500

70.5
73.0
75.5
78.0
80.5
200015001000500
2000
1500
1000
500
input balancing
outputbalancing
Contour Plot of Speed 10
Hold values: crowning:-1.0
52.5
55.0
57.5
200015001000500
2000
1500
1000
500
input balancing
outputbalancing
34
36
38
40
543210-1
2000
1500
1000
500
crowning value
outputbalancing

KPIV Set Up Optimization From DOE StudyKPIV Set Up Optimization From DOE Study
Key Process Input Variables
(KPIV - Xs)
Sound
Level
( dBA)
Speed
10
Speed
1
Speed
5
Speed
10
Shaft Teeth Crown 5 5 5 5
Armature Input Balance 2000 2000 2000 2000
Motor Output Balance 500 2000 500 500
Sound Qual i t y
Out put ( Y)
Crowning value – 5
Input balancing – 2000
Output balancing - 500

a. Restricted Noise dBA Spec.: USL<a. Restricted Noise dBA Spec.: USL<9090 dBAdBA, LSL>40 dBA, LSL>40 dBA
9184777063564942
LSL USL
Process Data
Sample N 16
StDev(Within) 1.47754
StDev(Overall) 1.74767
LSL 40
Target *
USL 92
Sample Mean 85.5312
CCpk 5.87
Overall Capability
Pp 4.96
PPL 8.68
PPU 1.23
Ppk
Cp
1.23
Cpm *
5.87
CPL 10.27
CPU 1.46
Cpk 1.46
Observed Performance
PPM < LSL 0.00
PPM > USL 0.00
PPM Total 0.00
Exp. Within Performance
PPM < LSL 0.00
PPM > USL 5.99
PPM Total 5.99
Exp. Overall Performance
PPM < LSL 0.00
PPM > USL 107.23
PPM Total 107.23
Within
Overall
Process Capability of Speed 10

Control PhaseControl Phase
BeforeBefore AfterAfter
Assembly Line Scrap – Abnormal NoiseAssembly Line Scrap – Abnormal Noise

b. Abnormal Noise Defect From Shopfloorb. Abnormal Noise Defect From Shopfloor
DPMO Z-Score Cpk Sigma Level
4000 2.65 0.88 4.15

T.I.R. Meter ImprovementT.I.R. Meter Improvement
BeforeAfter
BK Sound Meter DeviceBK Sound Meter Device
HardwareSoftware

S a m ple
SampleCount
60544842363024181261
20
15
10
5
0
_ _
NP = 4. 47
UCL = 10.79
LCL= 0
Befor e After
1
11
1
N P C h a r t o f D e f e c t _ 1 b y N a t u r e
T ests perfor m ed w ith unequal sa m ple sizes
Assembly Line SPC – Abnormal NoiseAssembly Line SPC – Abnormal Noise

JE Qual i t y Document Revi si on Ti t l e Responsi bl e Due Dat e St at us
DBDQC-CL-HC010-14 Rev.4
WPUN88C0127A Bracket Comm-
Quality Control Checklist
Simon Tan Nov-03 Done
DBDQC-CL-HC010-12 Rev.3
WPUN88C0126C Bracket Comm-
Quality Control Checklist
Simon Tan Dec-03 Done
9708197 Rev.03 Teeth Helica Gear Drawing Peter Lai Dec-03 Done
DBDQC-HA-QC010-01 Rev.02
Scorpion Motor R35000 (U9835)
PFMEA
Peter Zhou Mar-04 Done
DBEBC-PC-R101006 Rev.03 WPUN98B02005D W.I. Ping Zhao Jan-03 Done
DBEBC-EN-R350001 Rev.01 Noise Measurement Standard JN Ta Jan-03 Done
Corrective Activities ImplementationCorrective Activities Implementation

Process Trend Chart - AchievementProcess Trend Chart - Achievement
20000
15000
8000
5500 5000 4600
0
5000
10000
15000
20000
25000
30000
Nov Jan Feb Mar Apr May June July
MeasureMeasure AnalyzeAnalyze ImproveImprove ControlControl RealizationRealization
BASELINEBASELINE
GOALGOAL

JEHA Customer Situation Settlement
13
13
0
5
10
15
20
25
30
35
40
45
50
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
#CS
0.0
20.0
40.0
60.0
80.0
100.0
120.0
SCT/DCT
Sev erity 2-X Sev erity 1
# of CS cases Ent. DCT
SCT DCT Entitlement
JEHA Customer Situation Settlement
21
19
0
5
10
15
20
25
30
35
40
45
50
w5 w6 w7 w8 w9 w10 w11 w12 w13 w14 w15 w16
#CS
0.0
20.0
40.0
60.0
80.0
100.0
120.0
SCT/DCT
Sev erity 2-X Sev erity 1
# of CS cases Ent. DCT
SCT DCT Entitlement
BeforeBefore AfterAfter
Customer Field Return – High NoiseCustomer Field Return – High Noise

Scorpion Motor Noise - JE BB (part)-1

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