Team One Phase II Short Form1 Team Members Jeremiah Jones* David Karl Kris Pierson Kyle Renfro Brian Owens Michael Hipp** Dr. John W. Sinn*** *Assistant Team Leader **Team Leader ***Team Mentor

Team One Phase II Short Form 2 Project Plan To evaluate current resources available to the die cast industry for process data acquisition and the use of this data in a quality system.

Team One Phase II Short Form 3 Project Summary by Michael Hipp Plant Quality System –Quality system is a robust and thorough set of documented procedures –QS-9000 certified Current Status of Project –Reviewing data acquisition and analysis tools –Continuous improvement is the key Progress within Team One –Project focus improving –Continuous improvement is the key

Team One Phase II Short Form 4 Toolkit Applications by Kyle Renfro Toolkit 24 Applications –Normal Curve –Histogram –Standard Deviation Calculation Toolkit 25 Applications –P-Chart –X-bar & R chart –Data Collection, Recording and Analysis of Data

Team One Phase II Short Form 5 Toolkit Applications by Brian Owens Scrap Reduction by use of Inspection –Continuous Inspection –Automated Data Collection Machine –Catching Scrap at the Source Value of Charting –Converts Raw Data into Useful Data –Shows Trends that Can Help Process Improvement –Gives History of Defect/Cause Relationships

Team One Phase II Short Form 6 Information Reviews by Kris Pierson Statistical Process Control (SPC) –Decrease Scrap, Rework, and Inspection –Decrease Operating Costs –Increased Productivity –Increase Quality and Process Control The Improvement of Measuring Surface Quality –Evaluation of Surface Shape –Detects the Slightest Flaws that Impair Appearances –Improves Quality Assurance and Data Acquisition –Continuous Improvement of Quality Control Equipment

Team One Phase II Short Form 7 Information Reviews by Kris Pierson Die Casting Defects –Identifying and Eliminating their Cause –Problem Solving and Record Keeping Systems –Variable Statistics in the Production Process –Statistics and Process Capability Development and Evaluation of Sensor Systems –Document Data about Die-Casting Operation –Die-Cast Process Complex and Sensitive –All Cast Defects are Preventable –Test Engineering Theories about Die-Cast Operation

Team One Phase II Short Form 8 Information Reviews by Kris Pierson Attribute Charting –Method Used to Determine Process Problems –Statistical Process Control (SPC) –Data counts the Number of Times a Failure Occurs –Control Charts Monitor Process and Location Integrating HACCP and TQM –Electronic Vision Monitoring System –Monitors and Documents Deviations –Defect Attributed to Specific Unit Operation –Total Quality Management (TQM)

Team One Phase II Short Form 9 Information Review Abstract by David Karl Die Cast Machine –Uses Molten Aluminum to Make Parts –Quality Control in Die Cast Variables Advantages of Die Casting –Pieces per Hour –Lack of Extra Operations

Team One Phase II Short Form 10 Information Review Abstract by David Karl Quality Control on Die Cast Machines –Downtime Logging –Scrap Logging –Continuous Data Collection –Downloading/Uploading Machine Setups –Alarm/Report Editor –Closed Loop Controls

Team One Phase II Short Form 11 Information Review Abstract by David Karl SPC Charts –X-Bar and R Charts –Scatter Diagrams –HiLo Range Charts Reports –Shot Summary Reports –Data Log Reports –Hard Copy Reports

Team One Phase II Short Form 12 Evaluations of Team Henry and Team Dana by Brian Owens

Team One Phase II Short Form 13 Team One Self-Evaluations by Jeremiah Jones Team Evolution –Evaluation Sheets –Changes Made Team Meetings –Chat Room –Personal Meetings –Forming Goals

Team One Phase II Short Form 14 Team One Self-Evaluations by Jeremiah Jones Editing Our Submission Timeliness –How It Has Hurt The Team –Actions That Have Been Taken –Where We Stand Now

Team One Phase II Short Form 15

Team One Phase II Short Form 16 Weekly Task List

Team One Phase II Short Form 17 Thank you for your time! Please feel free to ask questions.