Cylinder Liner Boring Process Improvement Case Study Presented by Dr. Joan Burtner Certified Quality Engineer Associate Professor of Industrial Engineering and Industrial Management

ETM 627 Fall 2008Presenter: Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 2 Background Company is a supplier to an engine manufacturer Company is a supplier to an engine manufacturer  Company’s main product is a cast iron cylinder liner Customer has notified supplier that it will issue more stringent specifications Customer has notified supplier that it will issue more stringent specifications

ETM 627 Fall 2008Presenter: Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 3 Process Description – Flow Chart

ETM 627 Fall 2008Presenter: Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 4 Problem Definition - Defects Application of new specifications to historical manufacturing data to predict potential defects Application of new specifications to historical manufacturing data to predict potential defects

ETM 627 Fall 2008Presenter: Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 5 Problem Analysis – Potential Root Causes

ETM 627 Fall 2008Presenter: Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 6 Process Data – Initial Control Charts R Chart indicates that the process is out of control

ETM 627 Fall 2008Presenter: Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 7 Process Improvement – First Stage Investigation showed that a substitute operator was working when samples 6, 16, and 36 were taken Investigation showed that a substitute operator was working when samples 6, 16, and 36 were taken Interviews with line supervisors and regular operators uncovered the fact that the substitute operator had not been trained on the cylinder boring machine Interviews with line supervisors and regular operators uncovered the fact that the substitute operator had not been trained on the cylinder boring machine Corrective action: Provide training on proper machine operation Corrective action: Provide training on proper machine operation

ETM 627 Fall 2008Presenter: Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 8 Process Improvement - Results R chart indicates that the variability in the process is now in good statistical control R chart indicates that the variability in the process is now in good statistical control Xbar chart indicates presence of special causes Xbar chart indicates presence of special causes

ETM 627 Fall 2008Presenter: Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 9 Process Improvement – Second Stage Process Improvement Team (PIT) reviewed the cause-and-effect diagram and decided to investigate machine warm-up Process Improvement Team (PIT) reviewed the cause-and-effect diagram and decided to investigate machine warm-up Interpretation: Mean diameter decreases for first 90 minutes after start-up Interpretation: Mean diameter decreases for first 90 minutes after start-up

ETM 627 Fall 2008Presenter: Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 10 Process Improvement – Additional Results Process Improvement Team (PIT) brainstormed options Process Improvement Team (PIT) brainstormed options  Change operating parameters during warm-up  Have machine go through accelerated warm-up while not producing any parts  Leave the machine on over the lunch hour and start operation after lunch Team chose option 3 Team chose option 3

ETM 627 Fall 2008Presenter: Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 11 Case Study Resolution Both R and Xbar charts indicate process is now in control Both R and Xbar charts indicate process is now in control Mean Range Mean Range  7.60 at beginning of case study  6.60 at end of case study Mean Process Mean changed from to Mean Process Mean changed from to

ETM 627 Fall 2008Presenter: Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 12 Acknowledgments/ Further Reading  Case study (including figures) adapted from Chapter 6 of DeVor, R.E., Chang, T., and Sutherland, J.W. (2007). Statistical Quality Design and Control: Contemporary Concepts and Methods (2nd ed.). Upper Saddle River, NJ: Pearson Prentice Hall.  For additional information on problem-solving tools -- Westcott, R.T., Ed. (2006). Certified Manager of Quality/Organizational Excellence Handbook (3 rd ed.). Milwaukee: ASQ Quality Press.

ETM 627 Fall 2008Presenter: Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 13 Contact Information US Mail: US Mail: Mercer University School of Engineering 1400 Coleman Avenue Macon, GA Phone: (478) Phone: (478)