Duffy pad project

Duffy Pad Leak

• SUBJECT:
Duffy Pad Leak

• PROJECT LEADER:
Ray Peterson

Quality Control Pillar Board / Sterling Heights Assembly Plant Plant
Quality Control Pillar Board Sterling Heights Assembly

Duffy Pad Leak

Sketch of Defect

Flash on Inner
Rubber Seal


Sketch of Phenomenon

Body of Vehicle

Water Leak

Excess Flash
Gaps Formed
from Excess
Flash

Quality Control Pillar Board / Sterling Heights Assembly Plant

Data Stratification
Date VIN Problem Shift found on Water Test Shift problem occurred at on line 11-May 275130 Seated Leak 1 1
6-Feb 204585 Unseated Leak 1 N/A 11-May 277287 Seated Leak 2 2
25-Feb 221174 Seated Leak 1 N/A 11-May 281480 Unseated Leak 1 2
1-Mar 218550 Seated Leak 1 N/A 12-May 279582 Seated Leak 1 1
12-May 289903 Seated Leak 2 1
15-Mar 241553 Seated Leak 1 N/A
14-May 282515 Unseated Leak 1 1
19-Mar 242618 Unseated Leak 1 N/A
20-Mar 238371 Seated Leak 2 1
21-Mar 237130 Unseated Leak 2 1
5-Apr 251626 Seated Leak 1 2 15-May 297116 Seated Leak 2 1
17-Apr 261609 Unseated Leak 1 1 17-May 287157 Unseated Leak 1 2
18-Apr 249868 Unseated Leak 2 1 17-May 293761 Seated Leak 1 1
26-Apr 260993 Unseated Leak 1 2
1-May 252326 Unseated Leak 2 2 31-May 292691 Seated Leak 1 1
1-May 253677 Seated Leak 1 1 1-Jun 284861 Seated Leak 1 1
1-May 261951 Unseated Leak 2 1 1-Jun 289076 Seated Leak 1 2
5-Jun 307234 Seated Leak 1 2
6-Jun 279885 Unseated Leak 1 2


Normalized Data of Defective Duffy Pads
1.10

1.08
1.05
1.05

1.00
C/1000 Occurrences

0.95

0.90

0.91

0.85

0.80
JSC41 JSD41 JS27


Total number of Duffy Pad Leaks by Shift (3/18-6/18)
60

50

57
Number of Occurances

40 50
30 39
39
20

10

0
1st Shift 2nd Shift

Seated Duffy Pad Leaks by Shift Unseated Duffy Pad Leaks by Shift
(3/18-6/18) (3/18-6/18)
1st shift 2nd shift 1st Shift 2nd Shift

38%
47%
53%
62%


Seated Leaks vs. Unseated Leaks (3/18-6/18)
40

35

30
Number of Occurrences

25

20
Seated Leak
Unseated Leak
15

10

5

0
February March April May June

Month


Duffy Pad Leak
``
Line
Machine
Date
5W,1H Analysis Sheet
6/5/2012

Initial Phenomenon:

Duffy pads are experiencing a water leak

* What does the phenomena look like? What product,
What machine, material w as being used? What size? Water leak on duffy pad through BIW opening located under IP.

* Whe n did the phenomena occur? When in the sequence
The phenomena is discovered during water testing. The phenomena
When of operation; startup, continuous running, intermittent
problem, shutdow n, changeover? occurred during continuous running.

* Whe re did you see the phenomena? Where on the
Where equipment or material did you see the phenomena? The phenomena has been spotted on the JSC41, JSD41, and the J27.

* Who does it ef f ect? Everyone? Or is it less of a problem The phenomenon effects the quality team, SQA, chassis UL, chassis
Who f or some individuals or teams? (If so, w hat inf o can they
of f er?) Is it skill related? TL and chassis assembly.

* Which trend or pattern does the phenomena have? E.g.
Is the phenomena more f requent on Monday mornings? The condition is random in nature and affects both shifts. Roughly
Which Af ter a change-over? Or is it random in nature? Which
direction does the phenomena happen in? (Note: Not many fifty-six percent of total defects take place on the first shift.
phenomena are truly random!)

Optimally there should be no water leak on the duffy pad. The rate
* How is the state of the equipment changed f rom the
How optimal? How many times does the problem occur? of apperance of the phenomena has steadly increased since
February 2012.

Revised Phenomenon
Water leak on duffy pad through BIW opening located under IP. The phenomena is discovered during water
testing. The phenomena occurred during continuous running. The phenomena has been spotted on the JSC41,
JSD41, and the J27. The phenomenon effects the quality team, SQA, chassis UL, chassis TL and chassis assembly.
The condition is random in nature and affects both shifts. Roughly fifty-six percent of total defects take place on
the first shift. Optimally there should be no water leak on the duffy pad. The rate of apperance of the phenomena
has steadly increased since February 2012.


Duffy Pad Leak

Revised 4M
Material Man
Duffy Pad

Operator following SWI OK
OK Inner Component BIW Hole not to Spec

OK Clips

OK Rivets Operator Using Wrong Tool OK

NOK Inner seal Paint Sealant covers BIW hole
1
Operator Trained

Non-robust Design

Seated Duffy Pads
are Leaking. See
5W1H for more
detail.

SWI Correct

Clear and Understandable OK
Provides Detail OK

Improper method of handling material

Machine Method


Duffy Pad Leak
4 M Investigation Sheet
DETAILED ACTIVITIES ON 4M-ANALYSIS
Description Activity Data Who Target Status
MATERIAL
Checked 50 vehicles/day for two weeks
Is the inside edge of the body where No signs of jagged edges found after checking a sample
looking for inconsistancies on the inside R. Peterson June 1st OK
the duffy pad sits flush? size of 500 vehicles
edge
Checked 50 vehicles/day for two weeks
Is the outside edge of the body where No signs of jagged edges found after checking a sample
looking for inconsistancies on the outside R. Peterson June 1st OK
the duffy pad sits flush? size of 500 vehicles
edge
Compared defective duffy pads against ones Clips were shown to be resilient regardless if defective or
Are the clips loose on the duffy pad? R. Peterson June 5th OK
which were shown to be acceptable not
Are the clips damaged on the duffy Compared defective duffy pads against ones Clips were shown to have similar dimensions regardless if
R. Peterson June 5th OK
pad? which were shown to be acceptable defective or not
Are the duffy pads out of position after
Checked 50 vehicles for unseated duffy pads Duffy pads are correctly seated R. Peterson June 6th OK
install?
Slight pressure easily unseats duffy pad regardless if
Are the duffy pads a non-robust Checked duffy pads after install for any signs
defective or not. However, this issue is not causing the leak R. Peterson June 6th OK
design? of weakness
in the duffy pads
Has the design of the inner
Examined 50 fresh stock along with 10 failed Fresh stock duffy pads were shown to be similar to ones
component of the duffy pad been R. Peterson June 6th OK
duffy pads which were compromised
compromised?
Are the rivits found on the duffy pads Checked defectve duffy pads along with fresh Rivets on both defective and acceptable duffy pads were
R. Peterson June 6th OK
defective in any way? stock shown to be structurally intact
Seal on defective duffy pads differs from those which are
Are the duffy pads that are shipped Compared defective duffy pads against ones
from the supplier free of defects? which were shown to be acceptable
acceptable. Defect is approx. 2mm thick, 8mm long, and R. Peterson June 7th NOK 1
10mm left of the longest clip
MAN
Are operators following SWI for duffy Observe operator's installing duffy pads on
Operator performed install per SWI R. Peterson. May 29th OK
pad install? 20 vehicles for consistency.
Are operators using the wrong tool to Observe operator's installing duffy pads on
Operator performed install per SWI R. Peterson. May 29th OK
perform install? 20 vehicles for consistency.

METHOD
Is SWI clear and understandable? Review duffy pad install SWI SWI is clear to understand and is written correctly R. Peterson May 30th OK
Does the SWI provide detail on the
Review duffy pad install SWI SWI provides in-depth detail on procedure R. Peterson May 30th OK
job?
MACHINE
N/A


5-WHY
Effect Potential Causes Corrective Action
Duffy Pad Water Leak 1-WHY 2-WHY 3-WHY 4-WHY 5-WHY Description WHO WHEN

Duffy pad is
Excess flash Inner seal is Lifter located PIC containment of
not fully seated
against
on inner seal defective from at supplier is PIC excess flash on inner
R. Peterson,
E. Lantto,
6/10/2012 1A
of Duffy pad supplier damaged sealant of duffy pad
vehicle's body

1

OPL created to make

OPL
operators aware of
excess flash located
R. Peterson,
6/12/2012
1B
G. Marquardt
on inner seal. OPL
implemented by TL

Worked with SQA to R. Peterson,
SQA
achieve a clean point A. Hadorn,
6/22/2012 1C
on all duffy pad stock B. Bush,
incoming A. Del Real


Duffy Pad Leak

"QC" Pillar - Kaizen Journal of Activities
???? SK Duffy Pad Leak
# Activity Who Target Status Note

1 Complete Data Collection R. Peterson, J. Nava 6/18/12

2 Complete 5W1H and 4M R. Peterson 6/06/12

3 Complete 5-why R. Peterson 6/12/12

4 Review SWI R. Peterson 6/07/12

Contacted supplier about excess flesh located E. Lantto, B. Bush, A.
5 6/08/12
on inner seal of duffy pad Hadorn

Add OPL at Chassis install for excess flash on
7 R. Peterson 6/12/12
duffy pad
Clean point has been labeled
E. Lantto, B. Bush, as such since 6/7/12 by US
8 Clean point achieved by supplier 6/22/12 Farathane. However as of
A. Hadorn 6/18/12 clean point has not
been achieved.


Sketch of Solution
After Solution
Before Solution
Flash on Inner
Rubber Seal

No Flash


Long Clip: Defect
located 10mm left
of edge


Duffy Pad Leaks Found Since Start of Project (5/25-6/18)
5
1

4
Number of Occurances

3
1B

2

1

1A

0 Series1, 0


1B ONE POINT LESSON (OPL)
Basic Knowledge Improvement X Problem Awareness

SHAP Dept: Chassis (9170) Zone #1 Team # 5 Station 1221 Col H20 Completed by: R. Peterson Doc # WCM2012-0612

WHAT: Duffy Pad Install (Decking Cell) Model: JS 6/12/2012

HOW WHY
Before install If the duffy pad
d
check inner seal has flash on the
of duffy pad to inner seal, it
make sure that no will not seat
excess flash is properly.
present. T he flash
is located 10mm
to the left of the
long clip

Date of Training

Trainer
WCM009-0
Pupil


Duffy Pad Leak
5 Questions for Zero Defects
ANSWER SCORE
# QUESTION 1 3 5 PHASE 0 PHASE 1 PHASE 2 PHASE 3 PHASE 4

Are the material quality
1 A list of characteristics exists The check method exists It's easy to check 1 5
characteristics clear?

Exist the incoming material There is no standard, but some Standard of control exists Effective and efficient control
2 1 3
control standard? occasional checks exist (incoming material inspection ) (error/mistake proofing,etc.)

Cpk is too low, and there are
The supplier capability is 1<Cp<1.33, and there are Cpk>1.33, and there are no
3 many problems with the 1 3
sufficient sporadic problems problems
supplier

The part is in Stages 1-4 of the 8 The part is in Stages 5-7 of the 8 The part is in Stage 8 of the 8
Which stage of QC incoming
4 Stages of Incoming Material Stages of Incoming Material Stages of Incoming Material 1 1
material it's guarantied
Control Control Control

Standard countermeasures are A robust process exists and can
Is it easy to restore a correct No, the incoming material must
5 applied to compensate compensate for material 3 3
material characteristic? be scrapped
(process adjustment, etc.) anomalies

TOTAL 28% 60% 0% 0% 0%


Duffy Pad Leak

Initial Benefit/Cost Analysis
Cost includes team root cause B/C = 7.22
analysis $1,283.28
Benefit includes annualized
repair/re-process cost
avoidance, and over-manning
elimination
$9,269.64

Initial Benefit / Cost Analysis
Repair 18/month=>216/year Root Cause Analysis Hours Peterson 30
Hours Repair/Year 216 Ken (Water Test) 9
Hourly Cost Repair $37.96 Heavy 9
$8,199.36 48

Cost of Replacement Part $4.96 Hourly Rate Intern $20.00
Replacement Parts/yr $1,070.28 Hourly Rate for Repair $37.96
Total Manpower Cost $1,283.28
Total Benefit $9,269.64
Total Cost $1,283.28
B/C Ratio 7.22


Duffy pad project

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