The document discusses a project to reduce failures of heat sink mounted components by improving the heat sink assembly process. It aims to determine the highest risk component, identify correlations between field data and production data, set goals to reduce defects by 50%, and analyze the current process capability to identify non-capable processes in need of improvement.

3. Major Field Heat Sink type of Component Problem is the Voltage regulator ICX3400 used on CA Chassis . Define FIELD DATA

4. Define In Process Data There is a direct CORROLATION between the FIELD Data (previous Page) and the In Process Data (above) showing that CA ICX3400 is the component that most fails . Based On this the Team will Focus on Improving the In Process indexes for CA Chassis ICX3400 since by doing so we can Safely State that we will Improve the RELIABILITY RISK FACTOR IN THE FIELD of all Heat Sink Type Components regardless of Family . The Improvement will come from a Stable Heat Sink Assy. Process and the required Control that this team will set .

5. Define In Process Data There is a direct CORROLATION between the FIELD Data (see Page 3) and the In Process Data (above) showing that CA ICX3400 is the component that most fails . Based On this the Team will Focus on Improving the In Process indexes for CA Chassis ICX3400 since by doing so we can Safely State that we will Improve the RELIABILITY RISK FACTOR IN THE FIELD of all Heat Sink Type Components regardless of Family . The Improvement will come from a Stable Heat Sink Assy. Process and the required Control that this team will set .

6. GAP = 0.18 Goal = 50% defect reduction (in PPM) Define Project Goal

7. A Define Failure Logic Tree

8. A Define Failure Logic Tree

10. Measure Gage R&R Analyze The Short Term Method was used for Gage R&R since No Repetitions Can be Done on the Same Part (Torque) . And as can be seen our Gage R&R % Tolerance is 64.9 . NOT ACCETABLE Gage R&R Analyze All Conditions being the same we have variance between Operator and Operator The ROOT CAUSE of the Variance Needs to Be Found and Eliminated Before continuing with this project .

11. Measure Gage R&R #2 After the first Gage R&R Study produced Unsatisfactory results the Process was Study Closely . Was was noticed that operator at times do the TORQUE operation and than they RE-Torque Same part Again and Again . At this time the operator was instructed in the proper Techniques doing the operation . Basically torque until the clutch engages for the first time at this time do not re-torque (No double Clicks) Yielding the following Gage R&R . This Gage R&R is now acceptable since it is <30% .

12. Analyze Process Capability Study Plan GUN # & Operator 10 Samples Start Normal Distribution ? YES No Increase Sample size Graph Process Capability Process Capable ? YES No Investigate & Eliminate Variance This is the Process Capability Plan for the Heat Sink Assy. Area . Each Gun/ Operator Combination used for Assembly of CA Heat Sinks sinks will be study . If any are found to be Not Capable of operating within its Specs. The Assignable Cause will be INVESTIGATED , ELIMINTAED and CONTROLLED . This arrangement is required since this area is configured as a CELL Type work environment were each station does its complete Assy.

13. Analyze Tools To Be used In The Study Cal. Lab. Results for this Instrument. OK to use for Gun Set-up Torque Meter for gun Set-up Applied Torque Auditor Cal. Lab. Results for this Instrument. Show well suited to use for studying Applied Torque

14. Analyze Current Process Capability The Normality test above tells us that our process has a Normal distribution characteristics thus our 10 samples can be used to graph a process capability .

15. Analyze Current Process Capability Study The above shows that Gun 05 coupled with operator “ANA” are Capable of producing parts with Applied Torque within the specified Limits . Combined with Operator “ANA” CONCLUSION

18. Analyze Current Process Capability