1. Feedback of Scrap Convergence Plans
Wuhan lens lines
Frédéric MORET
Qiang ZHOU
Mar 30, 2007

2. Wuhan lens line #1 Targets From 55% to 20% from February 1st, 2007
Reduce average scrap rate:
From 55% to 20% from February 1st, 2007
From 20% to 10% from April 1st, 2007
Achievement
Operation by Wuhan team alone
Convergence team in Wuhan (3 weeks)
Convergence team in Wuhan (3 weeks)
Monthly average
24%
16%
Up to March 27

3. Wuhan lens line #1
Weekly results

4. Wuhan lens line #1 Scrap Convergence Plan
Wuhan team + 8 people of Branch process team (spending in total 6 weeks in Wuhan)
Step I: Analysis
Step II: Quick savings by basic operation & maintenance improvements
Organization and training of operation & maintenance teams
Step III: Stabilization by design standardization of all tools (molding & coating)
Organization & training of plastic engineering & process engineering teams
I: Analysis
II: Quick savings
Scrap rate (%)
III: Stabilization
Before plan
Achieved
Target

5. Trainings Step II (January 2007) Step III (March 2007)
Lens line jig design & manufacturing OJT
Lens line jig tuning OJT
Lens molding
Cleanliness in lens line
Jig management in lens line
IRIS
Inspection and logistics in lens line
Step III (March 2007)
Development of tools, jigs & fixtures for lens coating
Lens molds: design & maintenance improvements
TPM for lens coating line
Injection screw & barrel cleaning OJT

6. Organization Branch team Wuhan team 7 people involved (8 in January)
Period in Wuhan prolonged from March 23 to 30 for 2 people in order to complete some actions
Wuhan team
January 26th: APU manager nominated as Division Champion
February 1st: New supervisor & coating process engineer nominated
March 22nd: Transfer of jig & fixture development from industrial dep to APU
March 22nd: Launch of Division industrial standardization committee
Proposal for improvement of part development process

7. Part development
Many issues because part design rules are not systematically applied
Why?
CIP part design process not systematically applied:
Formal Design Reviews (DR)
Completed check lists
Participation of plastic engineering Expert & specialists to DR
Improvement proposals
Nomination of process Specialists
Tooling (L. Ma), injection (C.Y. Hu), thermoset coating (Y. Yu), lens coating (Z. Jia), metallization (F. Tang), assembly (Y. Guan)
Training schedule of process Specialists by Experts
Semi-monthly PEN (Plastic Engineering Network) webinars
Trainings by Experts in Wuhan
Launch of a Division industrial standardization committee
To build a database of Division industrial standards & related part design rules
Formal approval of design by process Specialists during DR
Formal & systematic participation of process Specialists and Expert (J. Ortiz)
Systematic review of 3D drawing according to Branch & Division design rules
Formal process design rule check list signed by PE + Expert

8. Status per product on March 30
DPCA R23: Running at 7% scrap rate on Saico line (demonstrated on last batch March ).
DPCA T21: Running at 9% scrap rate on Saico line (demonstrated on last batch on March 12).
Nissan X11J: Mold ready to run with a 2% scrap rate. Fine process tuning in progress on Eisenmann line. Clear action plan, signed by each person in charge, achievable by Wuhan team alone with its present resources to start production and achieve <10% scrap rate by April 20.
DPCA T11 (product to localize): Ready to run on Saico line with a scrap rate < 10%.
VW B6 (new product): Ready to run on Saico line with a scrap rate <15% (17% achieved during March 26 night shift), and clear action plan achievable by Wuhan team alone with its present resources to improve down to <10% scrap rate by April 30.
DPCA B53 (product to localize): Clear action plan, signed by each person in charge, and achievable by Wuhan team alone with its present resources for mold improvement, in order it is ready to run on Eisenmann line with scrap rate < 10% by May 31.
DPCA T53 (product to localize): Clear action plan, signed by each person in charge, achievable by Wuhan team alone with its present resources in order it is ready to run on Saico line with scrap rate <10% by May 31.
DPCA T63 (product to start): Clear action plan, signed by each person in charge, achievable by Wuhan team alone with its present resources in order it is ready to meet all customer milestones on time until SOP on Eisenmann line in July, and to run with a scrap rate < 10% by July 31.

9. SOP of Eisenmann line Line started with Nissan X11J Molding Coating
Equipement: Defect in screw detected during cleaning – Re-machined by supplier & back on April 4
Product & process: No issue in mold (is currently running with 2% scrap rate)
Coating
Equipment: Commissioning not totally completed, but line available for process tuning
Product & process: Good lens position found, fine process tuning in progress (IR, UV & thicknesses)
Target: Complete line ready for production on April 10
Support of Branch team after March 30
P. Vottero (maintenance) in Wuhan for advices regarding line commissioning and acceptance
F. Kanazawa (process) in Bobigny for checking part quality (bring back by team & sent by express mail) and advices regarding process tuning
Back-up plan
If targets are not achieved from March 30, F. Kanazawa will come back to Wuhan