Adhesive Project Example

Problem Statement The amount of adhesive consumed in the assembly operation is higher than specified by engineering, resulting in significantly higher production expenses, which impact profitability of the product. Target: Identify the causes of excessive adhesive consumption and reduce the usage of adhesive in the assembly line operation by 400%. Critical To Quality - CTQ Applying the specified amount of adhesive is essential to bond strength. Applying excessive adhesive causes costs to exceed targets. Benefits Achieved $500,000 savings in material costs for adhesive.

Projected Usage For the Year Metrics Adhesive usage and cost Adhesive Volume/Cost Total Plant 1st Qtr Usage Projected Usage For the Year Brought in house 14,983 Gal. $174,738 56,479 Gal. $658,689 Usage Per Projected Specification 3,542 Gal. $41,305 13,353 Gal. $155,731

Cause-Effect Diagram Methods Machines Manpower Measures Limit switch set up (too high causes excessive adhesive remaining in drums) Purging process - - Drum’s change over process Over use of adhesive during assembly processes Pressure set up - - Nozzles timing Nozzles Height - vs. Panel nest - Needed training on spec’s. - In- Process Measurement system -Leaking during application Machines Manpower Measures

Current dimensions data: Base line D-M-A-I-C

Current Process not capable- Negative Sigma Level

DOE - Optimize Pressure & Time Settings for the dispensing nozzles

Results Main Effects Plot Regression Model Results used to optimize settings for nozzles Regression Analysis: Diameter versus Pressure, Time The regression equation is Diameter = - 39.0 + 0.740 Pressure + 1.61 Time Predictor Coef SE Coef T P Constant -38.985 8.038 -4.85 0.000 Pressure 0.73956 0.09967 7.42 0.000 Time 1.6121 0.2100 7.68 0.000 S = 1.596 R-Sq = 94.0% R-Sq(adj) = 93.5%

ADHESIVE'S SPOTS SIZE Visual Aid WRONG TOO BIG WATCH FOR THIS DEFECT TOO SMALL ADHESIVE'S SPOTS SIZE 23 mm LOWER SPEC. 25 mm TARGET WRONG TOO BIG 27 mm UPPER SPEC.. WATCH FOR THIS DEFECT

BEFORE CHANGING ADHESIVE Visual Aids To avoid Adhesive spillage… When plate is here There is 25% of adhesive remaining in this drum BEFORE CHANGING ADHESIVE DRUMS CHECK FOR: Piston is at bottom Piston is here The drum to be removed from the line is empty. The piston is all the way down to the bottom of the drum. Air pressure closed for drum to be changed T-valve closed for the drum to be changed. T-valve open for the remaining drum. T-valve AFTER CHANGING ADHESIVE DRUMS CHECK FOR: LOSS $11.7/gallon T-valve is open for both drums. Air lines open for both drums; if not, one drum will pump Adhesive to the other.

Measurement tool for Adhesive spots Measurement System Measurement tool for Adhesive spots Prototype II Gage type: Go / no go 23mm 27mm 1000mm 60mm Lower specification limit Higher specification limit Material: Plexiglass

Process Capability for Diameter Improved Ppk= 3.1 Actions: Material handling Changes Optimized Application Settings Project Results 1st Qtr Cost Improved Process Cost Difference Yearly Savings $ 0.58/panel $0.24 /panel $0.34/panel $503,000 Process Capability for Diameter Improved Ppk= 3.1