Daily Yield Pareto – monitor the
yield on a daily basis to ensure issues are not re-occurring. Action as
appropriate
Process map – if the line
yield drops below 85% yield
Team meetings - weekly updates on yield to Product Builders to
keep the focus
The
control phase of the project kicked off on the 18th March. All the
tools used in the earlier phase enabled us to improve our yield from a Rolled
Throughput Yield of 22% to 69.68%. From the below Pareto coil issues and kinks
had reduced but we had another issue, delamination. Our focus was then on the lamination
station and the horizontal laminator. The air pressure on the laminator was at
20 psi when it should have been at 25 psi which meant the units were getting too much
heat.
The
next issue we encountered was fibres on the units which we noticed at the
mandrel removal station. For this issue we cleaned all material before using, cleaned
the trays the units were being stored in before using and we also cleaned the
bench tops before each lot was started. The Pareto will be of huge benefit to us as it is
a visual reminder of the issues we will see going forward.
Daily Pareto
Process Map
The
process map we conducted at the Hub Attach station proved to be a vital
tool for us in hi-lighting the issues being caused at that station with regard
to kinks. This tool will be used going forward to enable us to resolve any
issues we may encounter in the process.
Weekly Team Meetings
Team
Meetings are conducted by me weekly. Going forward the Engineer for the line
will present on the issues from the Daily meetings to the Product Builder team.
In the past we have hi-lighted issues of concern to this group and have found
that they respond very quickly to help solve the issues but then once the
initial reaction has died down we tend to see some of the same issues come back
again. We feel that a weekly update will keep the focus for this team and
improve the yield and output of the line.
