2. Project Name : To reduce sealing open rejection 1.3 % to 0.03 %
Date ( Revision by) :
Prepared By : KHUSHAL R. TALHAN
Approved By: AMOL KHANDAGALE
BUSINESS CASE :
OPPORTUNITY STATEMENT (HIGH LEVEL PROBLEM
STATEMENT )
Vishay componenets India pvt ltd, it is a
world largest manufacture of semiconductor
and passive components.
To improve the yield , rejection percentage ,and cost of poor quality.
.
DEFECT DEFINATION : metal is not fully covered entire area by plastic
film.otherwise plastic film is opening during next operation.
GOAL STATEMENT : PROJECT SCOPE
Reduce the rejection of sealing open and thread open of Film capacitor. Process start point : AT WINDING STAGE .
Expected Saving / Benefits
COST OF SAVING 1,60,16000
Process End Point : FINAL CONTROL INSPECTION STAGE
Project Plan : Team :
Task / Phase
Start Date End Date
Actual
Date Name Role
Commitme
nt
Define 07-Jan-14 22-Jan-14 22-Jan-14 KHUSHAL TALHAN DATA COLLECTION 95%
Measure 20-Feb-14 22-Feb-14 24-Feb-14 TANAJI PHALKE ACTION 99%
Analyse 10-Mar-14 28-Mar-14 30-Apr-14 RANJIT MALGAR MONITORING 99%
Improve
12-Apr-14 03-Apr-14 15-Apr-14 GANESH SATAV
HORIZONTAL
DEPLOYMENT. 99%
Control 06-May-14 22-May-14 30-May-14 AMAR JANGAM MONITORING 99%
TEAM / PROJECT
CHARTER
4. SIX SIGMA DMAIC PHASE
Identify problem DEFINE
Practical Problem
MEASU
RE
Root cause
analysis
ANALYZ
E
Problem
solution
IMPROV
E
Problem control
CONTRO
L
5. Total Front End Yield in year 2013 – 92.1%
Breakage of 7.9% rejection
Mechanical defects : 4.12 %
Electrical defects :3.78 %
The process engineering dept has taken project of Electrical Defects
Focused on mechanical defects
1.
33
Why theme is selected ?
0.00
20.00
40.00
60.00
80.00
100.00
Reject.%
Break up of mechanical rejects in % 1.3
%
6. Cost of poor Quality
$
Issue No. of pieces
Scrapped in 2014
Sealing open 3.6 mln
Cost of poor quality = 3600000*5 RS = 1800000 RS
$ 494K
7. 1. TURNOVER: RS 1993.4
MLN
2. PBT :RS 176.3 MLN
To improve film cap yield 85%
Dept action plan : Reduction in
rejection of sealing open issue by
50%
Linkage to quality Policy
8. Project leader
A.T.Khandagale
(Maint. Engineer)
T.M.Phalke
(Maint. Engineer)
K.R.Talhan
(Quality .Engineer)
G.B.Satav
(Jr.Maint. Engineer)
Malgar R.S.
(Prod. Operator)
Assembly follow-up
Defect mode
analysis
Standardization
Data collection
Equipment
Improvement
Result check
Solution action
Data collection
Assembly follow-up
Result check
Horizontal deployment
Data collection
Routine Check
Production trials
Result check
Team Organization
9. No. of Meetings Held : 10
Meeting Calendar
Date 7.01.15 22.01.15 20.02.15 10.03.15 28.03.15 12.04.15 3.05.15 6.06.15 25.06.15 21.07.15
Meeting at
3.00 p.m.
Team
Attendanc
e
100% 100% 80% 100% 100% 80% 100% 100% 100% 100%
In that meeting we got root cause of sealing open
problem.
10. 1. Data collection
2. Brainstorming
3. Pareto analysis
4. Ishikawa diagram
5. Why-Why analysis
6. Variable search( DOE)
Tools used to solve problem
11. Activity planning (Gantt) Chart
Activities Planned Responsibility Wk No. W1402 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44
Data collection of sealing
open issue
KHUSHAL
Planned
Actual
Analysis of available data Team
Planned
Actual
Action Plan as per
analysis
T.M.Phalke
Planned
Actual
Execution of actions Satav/Kulkarni
Planned
Actual
results confirmation on
machines.
KHUSHAL
Planned
Actual
Horizontal Deployments
on all machines groups,
Satav/Kulkarni.
Planned
Actual
13. Define problem – Sealing open
Good
Bad
Bad
Flap open
Thread open
Rejection 30%
Rejection 70%
14. Measure problem – Sealing open
Sealing problem faced on winding stage
Following are the different winding machines and sealing open
percentage as per following
Rejection
of sealing
issue is
1.33%
Machine
Name
Present sealing
rejection
Present sealing Profile
Stella
Romeo
0.97 50% Land Sealing
Stella ERO 0.01 Cover film + 50% Land
VHW 0.05 Cover film + 50% Land
Ariane 0.2 50% Land Sealing
Cosmos 0.15 50% Land Sealing
AVM 0.04 50% Land Sealing
BC 2000 0.01 Cover film + 50% Land
From above study it is finalized that sealing open rejection on
stella Romeo machine
15. Data collection – Sealing open for
stella romeo m/cs
Date Machine No.
Foil
Micron
Sealing
temp
Sealing
Profile
Problem Observed Action taken
18.02.2014 Stella fl. 6e-5 12 310 Square Threads open Clean the pencil.
20.02.2014 Stella fl. 6e-9 6.2 290 Square Flap open Sealing not parallel so adjust grub screw.
22.02.2014 Stella fl. 6e-4 6.2 280 Square Threads open Sealing not parallel so adjust grub screw.
25.02.2014 Stella6e-1 6.2 280 Plain Flap open Clean the pencil and adjust the grub.
27.02.2014 Stella fl. 6e-2 12 320 Square Threads open Sealing not parallel so adjust grub screw.
02.03.2014 Stella fl. 6e-6 6.2 280 Square Threads open Reduce sealing temperature
04.03.2014 Stella fl. 6e-10 12 310 Square Threads open Sealing not parallel so adjust grub screw
05.03.2014 Stella fl. 6e-4 6.2 290 Square Flap open Sealing not parallel so adjust grub screw.
08.03.2014 Stella fl. 6e-5 12 310 Square Threads open Reduce sealing temperature
10.03.2014 Stella fl. 6e-11 12 320 Square Threads open Sealing not parallel so adjust grub screw.
11.03.2014 Stella fl. 6e-12 12 310 Square Threads open Clean the pencil and adjust the grub
13.03.2014 Stella 6e-5 6.2 280 Plain Flap open Sealing not parallel so adjust grub screw.
15.03.2014 Stella fl. 6e-9 6.2 280 Square Threads open Clean the pencil and adjust the grub
16.03.2014 Stella 6e-8 12 310 Plain Flap open Sealing not parallel so adjust grub screw.
17.03.2014 Stella fl. 6e-4 6.2 280 Square Threads open Clean the pencil and adjust the grub
19.03.2014 Stella fl. 6e-2 6.2 290 Square Threads open Clean the pencil and adjust the grub
21.03.2014 Stella fl. 6e-12 6.2 280 Square Threads open Reduce sealing temperature
Remark : Various trial conducted to find various causes of sealing open
fault,
no conclusion from trials.
16. Further analysis of sealing
open
Sr.No.
Types of
sealing open
Action taken to solve problem
1 Flap open Sealing not parallel so adjust grub screw.
2 Threads open
Clean sealing pencil
Set the temperature
Team decided to work initially on seal , flap open problem.
17. Why why Analysis of sealing flap open
Sealing pencil not parallel. Why ?
Grub Screw for parallel adjustment found loose. Why ?
After 1 week Compression spring pressure was getting
reduced at working temp. up to 350 °C . Why?
Present Compression spring material was
loosing properties at temp 350 °C.
Team Investigated and decided to replace material of
Grub screw and compression spring which can
sustain up to 600°C temperature.
Root
Cause of
the
Problem
18. Analysis of Comp. spring Material
Type of spring
material
Trial
Life of
spring(Spring
Length -14mm)
Not ok <10mm
Remark
Hard spring steel W1511
Not ok after one
week used
Not Suitable
Stainless steel spring
steel
W1512
Not ok after two
week used
Not Suitable
EN12070 W1512
Not ok after two
week used
Not Suitable
Inconel X750
Ni Cr 15 Fe 7 Ti Al W1514
OK even after 4
Week used(length
remain 14mm)
Suitable
Team decided to use material Inconel X750
19. Result after spring material
change
After changing compression spring – Sealing flap
open rejection is eliminated but sealing threads
open rejection is still 0.95% hence team decided to
study on threads open rejection
20. Horizontal deployment and standardization
Machines/Group
No. of Machines
Available
No .of Machines
Completed
Status
Stella Winding 46 46 Completed in week 1526
Standardization
Description
12 NC
Old New
Compression Spring 8203 110 32550 8203 110 32551
Sealing pencil compression spring replacement
frequency defined one year in Preventive Maintenance
Check sheet.
Sealing pencil spring drawing, stock no., changed in
Spare list..
21. Fishbone diagram – Sealing thread Open
Sealing
thread
Open
Untrained operator
Sealing pencil
not parallel
MAN
METHOD
MACHINE
Wrong
parameter
setting
WINDING
WINDING
Profile of
Sealing
pencil is
not ok
MATERIAL
FILM
No Method
for
inspection
Improper sealing
due to high speed
Sealing
open due to
low Temp
Sealing open
due to wrong
setting of
temp
Sealing
Pressure
not proper
Film MKT Film MKP
Film thickness
Solenoid
stroke not
standard
Compression
spring not ok
Serration
of sealing
pencil
worn out
Play in
Pencil
Guide way
Grub screw
loose
3
1
2
22. Sealing thread open – Ranking method
Variables Verification Data Influence
1) Sealing open due to wrong setting
of temp
Checked temperature and found range
280-320 in work instruction.
Yes
2)Serration of sealing pencil worn out
Verified and corrected during preventive
maintenance
No
3) Improper sealing due to high speed
Sealing speed is verified and found as per
instructions
No
4)Sealing pencil profile design is not
suitable.
Product observed under microscope
,spikes observed at non contact area of
pencil.
Yes
5)Film thickness
Difference in rejection quantity according to
film thickness
Yes
6)Play in Pencil Guide way Verified and corrected during preventive
maintenance
No
7) Solenoid stroke not standard Solenoid stroke length defined and Verified
during preventive maintenance
No
23. SR.NO. FACTOR DESCRIPTION LOW HIGH
1 Sealing temperature 280 320
2 Foil Thickness 6.2 12
3 Sealing profile(Land %) 50% 100%
From data analysis three parameters affects on sealing thread open
,Hence team decided variable search of these three parameters.
LAND
DEPTH
ROOT
SEALING PROFILE
Full Factorial Design
Factors: 3 Base Design: 3, 8
Runs: 16 Replicates: 2
