This document describes a problem solving project to improve the DMR tilt tables used in the Kansas City Integrated Stamping Plant. The project team designed and built new tilt tables that allow 360 degree rotation and multiple tilt positions for optimal part positioning. This will improve ergonomics and reduce nonconforming parts. The document also details analyses and improvements made to inspection processes, die changeover capabilities, press automation, and adding error proofing at the die shop to control quality.

1. 6-PANEL
STANDARD REPORTING METHOD
FOR PROBLEM SOLVING
Project Leader: Judd Anderson, Matthew Hunt
Process Owner: Scott Stiff / P702 Launch Team
Project Champion: Bill Hodges
Project Location: Kansas City Integrated Stamping Plant
Project Completion Date: 8/7/2020
DMR Tilt Tables P552 FL34-1550202-A
Regular Cab Roof produced at P702 ML34-1550202-A
level, additional antennae holes

2. 6-PANEL DEFINE
D M A I C R
Team Members:
❑ Scott Stiff - P702 Launch Leader
❑ Matthew Hunt, MPS Production Manager
❑ Archie Lyles - P702 Launch T & D Lead
❑ Chad Wuthrick - KCISP T & D ME
❑ Todd Zellak – KCISP Production Superintendent
❑ Therese Bayer (KCAP Blackbelt)
❑ Bill Hodges – KCISP Area Manager
❑ Brodie Schultz – Stamping Engineering

3. 6-PANEL
PROBLEM STATEMENT
DEFINE
D M A I C R
VOICE OF THE CUSTOMER: Wooden tables are not ergo friendly and not efficient.
CTQ/CTF STATEMENT (Critical To Quality/Flow) - Customer Requirement:
KCISP must have tables that articulate to produce high quality re[pairs / metal finish.
COST OF POOR QUALITY/FLOW:
Potential rework of material not metal finished to standards as a result of the constraints imposed by the tables
on the process. Ergo optimization will prevent injuries.
SCOPE AND GOAL:
Reduce nonconforming parts by 100%.and improve Ergo conditions.
Plant: KCISPLine: KCISP P2 SchulerArea: KCISP Press
Part/Process Name: KCISP Part / Op.
No Standard exists for the DMR
tables.

4. 6-PANEL
Method (Process)
Environment
Proper
Engineering
level of
parts
Manpower
Material Machine
- PCP / PVS - OK to run Process
D M A I C R
MEASURE
KPOV and KPIVs – Cause & Effect Diagram
X2
X1
Key Process Input Variables: In Y = f(X)
X1 = Tables must provide optimal position VOPQUN
X2 = Poor Ergo conditions potentially lead to injuries
- Poor Ergo conditions increase
potential for injuries.
- Tables do not articulate to
provide optimal position to
rework defects.

5. 6-PANEL
Key Process Input Variable X1 : Tables must articulate to provide optimal
position to rework material.
D M A I C R
ANALYZE & IMPROVE

6. 6-PANEL
Key Process Input Variable X1 : Tables must articulate to provide optimal
position to rework material.
D M A I C R
ANALYZE & IMPROVE
Tables were designed with a center post and bushing and
wheels on both sides for capability to rotate 360 degrees with
ease.

7. 6-PANEL
Key Process Input Variable X1 : Tables must articulate to provide optimal
position to rework material.
D M A I C R
ANALYZE & IMPROVE
We used and acme screw and block to allow the table wheels
to be locked in any position of rotation with only a quarter turn.
Plan to add a rubber cap to avoid damaging the wheel

8. 6-PANEL
Key Process Input Variable X1 : Tables must articulate to provide optimal
position to rework material.
D M A I C R
ANALYZE & IMPROVE
We fabricated a
mockup tilting lock
plate with 3 position of
tilt. Final machining
will add one more
hole per operators
request for an
additional position.
Current 2 pin
positions for flat and
15 degree working
angle.
Additional hole
location to allow
for a 38 degree
tilt for working
specific parts per
OP request.

9. 6-PANEL
Key Process Input Variable X1 : Tables must articulate to provide optimal
position to rework material.
D M A I C R
ANALYZE & IMPROVE
Team installed aluminum slats
with 1” holes drilled on 6”
centers to allow multiple pin
configurations and also the
ability to work inboards on the
panels without the need of
flipping the part over.

10. 6-PANEL
Key Process Input Variable X1 : Tables must articulate to provide optimal
position to rework material.
D M A I C R
ANALYZE & IMPROVE
All tilting locks and table slats have been
machined and are ready for install.
All table top frames are onsite and ready for
final assembly.

11. 6-PANEL
Key Process Input Variable X1 : Tables must articulate to provide optimal
position to rework material.
D M A I C R
ANALYZE & IMPROVE
Floor has been painted and all 11 frames
have been painted. Team used flat black
antiskid paint to eliminate slip hazards with
the metal dust. Starting install the week of
8/3

12. 6-PANEL
Key Process Input Variable X1 : Tables must articulate to provide optimal
position to rework material.
D M A I C R
ANALYZE & IMPROVE
With the new design the
Operator will be able to
Move the panel into
different positions to
eliminate potential
Ergo issues with
bending and reaching.
Also the part can be
worked from the under
side with out the need of
lifting the panel and
flipping it over.
This should help
eliminate moves that
would cost extra time.

13. 6-PANEL
Key Process Input Variable X1 : VOPQUN 050 PSW Procedure (resource).
Analysis :
7.3.2. Re-sourced Parts:
❑ VOPQUN 050 (continued)
• Review with the Assembly Plant Representatives the PSW Package, Current
Surface/Dimensional Data, Control Point Boards, QPS Sheets, Process Verification
Check Sheet, Process Control Plans, Packaging Specifications, Checking Fixture
Certification, WERS Alerts/Concerns. Additionally, review any background quality
information (i.e. TCO's, Work Plans, Global 8-D's, DMAIC concern Resolution details,
and Customer Concerns
• KCISP did not follow the procedure and make the appropriate contacts at DTP.
Action
❑ New Bullseye Panel produced before next run, DTG 6/8/2020
❑ A reference panel was obtained from KCAP Truck Body.
Results:
❑ All future resources must adhere to the procedure.
D M A I C R
ANALYZE & IMPROVE

14. 6-PANEL
Key Process Input Variable X2: PCP / PVS - OK to run process
Analysis: PVS / PCP
D M A I C R
ANALYZE & IMPROVE
First Piece Inspection Last Piece Off A) Appearance:
SC's
Free of Severe Die
Recoil Markings,
Wrinkles, Moderate or
Heavy Indentation,
Splits, Burrs, Impact
Lines or Other Issues
that Would Affect
Customer Satisfaction.
Visual Inspection 1 Panel Each Die
Set
Production Team
Inspector Submits for
Standard and Fill Out
Standard Tag SBU
7531
Reject Standard Notify Process
Coach, Correct Process and Initiate
Containment Procedure VOPQUG-
004
GO / NO-GO
Gage
B) Trim edge on DOP
Flanges
SC's
Trim edge is within
tolerance and burrs
within acceptable limits
Visual inspection for
burrs on both R &
L/Side
1 Panel Each Die
Set
Production Team
Inspector with Go/NoGo
Reject Standard, Notify Process
Coach, Correct Process and Initiate
Containment Procedure
C) # of Holes
SC's
17 Holes Visual inspection of
Holes per attached
Hole Count Sheet
1 Panel Each Die
Set
Production Team
Inspector number the
holes on the panel &
Enters on PHCS
Reject Standard, Notify Process
Coach, Correct Process and Initiate
Containment Procedure
D) Lot #
SC's
Lot # for Traceability Visual Inspection 1 Panel Each Die
Set
Production Team
Inspector Circle on
Panel & Enters on
PHCS
Reject Standard, Notify Process
Coach, Correct Process and Initiate
Containment Procedure
E) # of Bottomi Stamp
=1
SC's
Presence and legibility of
(1) Bottom Stamp
Visual inspection 1 Panel Each Die
Set
Production Team
Inspector Circle on
Panel & Enters on
PHCS
Follow Reject Standard Process,
Notify Process Coach, & Tool & Die
to verify die is on bottom. Issue
Priority1 Last Hit
F) Ford Logo
SC's
Presence of (1) Logo Visual inspection 1 Panel Each Die
Set
Production Team
Inspector Circle item
on Panel & Enters
PHCS
Follow Rejected Standard Process,
Issue Priority1 Last Hit.
Set Surface Std
Via FPA Process
SC's
Surface Standard / FPA Follow FPA Process 1 Panel 1st Hour of
Run
Production Team
Inspector Scores FPA
1st Hour of Run -
Record Data on FPA
Sheet. and Enters in
Quality Portal.
Reference during run,
then retain in Green
Rack
Process Coach Sets
Std.
Reject First Piece Inspection, Notify
Process Coach, Correct Process
and Initiate Containment Procedure
Hole count
was
performed
in error

15. 6-PANEL
Key Process Input Variable X2: PCP / PVS - OK to run process
(continued)
Action :
❑ Retrained P702 inspectors in PVS / PCP process.
❑ DTG 6/2/2020
Results
❑ Inspectors retrained in the PCP /PVS process and capable of following 1st Piece
Inspection Process.
D M A I C R
ANALYZE & IMPROVE

16. 6-PANEL
Key Process Input Variable X3: Die changeover capabilities
Actions:
❑ This die set was resourced to KCISP from DSP to facilitate Launching the newly installed
Schuler Press (KCISP P2).
❑ Die modifications were made at DTD for press compatibility.
❑ Die modifications were also performed at DTD to produce P702 level parts (2 added holes) in
addition to P552 level parts.
Results:
❑ 6/1/2020 Die function verified as correct.
❑ Additional capability will allow both P552 and P702 parts to be produced.
D M A I C R
ANALYZE & IMPROVE

17. 6-PANEL D M A I C R
ANALYZE & IMPROVE
FL34-1550202-A
2020 – P552
ML34-1550202-A
2021 - P702
Two
antenna
holes
added for
P702

18. 6-PANEL
Key Process Input Variable X4 : Press automated changeover capability
Analysis:
❑ Schuler Press is not engineered for fully automated changeover. All ports are constant
air.
Actions:
❑ Rework in process (added valves) to achieve capability to perform automated
changeovers.
❑ DTG 6/8/2020
Results
❑ This will allow the Schuler to run multiple unique parts per family of die sets and
facilitate service runs.
D M A I C R
ANALYZE & IMPROVE

19. 6-PANEL
Key Process Input Variable X5 : Error Proofing at DTP
Analysis:
❑ No Error Proofing at DTP.
Actions:
❑ Investigating adding Error Proofing at DTP.
❑ DTG TBD
Results
❑ Prevent recurrence of P702 panels cycling through line.
D M A I C R
ANALYZE & IMPROVE

20. 6-PANEL D M A I C R
CONTROL

21. 6-PANEL D M A I C R
CONTROL
Replication Opportunities
❑ All Future Resource actions will incorporate X1 and X2 strict adherence.