0. Adhesive Project Example

1. 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.

2. 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

3. 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

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

5. Current Process not capable- Negative Sigma Level

6. DOE - Optimize Pressure & Time Settings
for the dispensing nozzles

7. Results Main Effects Plot Regression Model Results used to
optimize settings
for nozzles
Regression Analysis: Diameter versus Pressure, Time
The regression equation is
Diameter = Pressure Time
Predictor Coef SE Coef T P
Constant
Pressure
Time
S = R-Sq = 94.0% R-Sq(adj) = 93.5%

8. 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

9. 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.

10. 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

11. 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