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October 19 th 2012. Melting Ice Flowers. The Eliminators. Vince Taylor Kristie Jones David Thomas. SEKISUI S-LEC AMERICA,LLC Technical Service Team Presenting for the 2012 Kaizen Competition. Automotive. Windshields. Side glazing (some models ). Introduction Sekisui Films.

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Melting Ice Flowers

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Melting ice flowers

October 19th 2012

Melting Ice Flowers

The Eliminators

Vince Taylor

Kristie Jones

David Thomas

SEKISUI S-LEC AMERICA,LLC

Technical Service Team

Presenting for the 2012 Kaizen Competition


Melting ice flowers

Automotive

Windshields

Side glazing (some models)

Introduction Sekisui Films

At Sekisui S-LEC America (SSA) we process Polyvinyl Butyral (PVB) resin into .76mm films

Located in Winchester, KY

Glass Laminators process the film into glass constructions by using heat and pressure


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Drop steel ball

Laminated Glass

Tempered Glass

What is S-LEC™ Film?

Single layer

Standard PVB

(cross section)

Tri-layer

Acoustic PVB High Performance Plastic (HPP)

(cross section)

Acoustic


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Business Background


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Business Background

Acoustic Sales and Share by Customer - tons


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PGW Creighton Acoustic Sales Timeline

PGW experiences Ice Flower defect

SSA Technical Service team immediately reacts with testing and trials

PGW experiences Optical Distortion issue with competitor’s acoustic

SSA acquires 100% PGW acoustic business

Acoustic sales begins to show significant increase

PGW began using SSA Acoustic

Zero Acoustic sales to PGW

2010

2011

2007

2009

2008

Big risk for SSA, PGW could have easily switched back to our competitor


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Situational Understanding

Examining an Ice Flower

Acousticlayer

(1)

Core

PGW Creighton lost $300,000 in warranty claims in 2011.

Crosssection (1)

(2)

Branch

Zoom-up picture

Bubble : Ice Flower Shape

Crosssection (2)

Bubble

Bubble

Bubble forms

Grows

Glass

Film

Glass

Penetrates SAF Layer

Expands & Branches Out


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Target

Reduce Ice Flowers at PGW Creighton by 90% and limit warranty claims to $30,000 in 2012


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Laminating process

Autoclave

Clipping Operation

PVB Expanding

De-airing Process

Assembly

Bent Glass Washing

Glass Separator


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Brain Storming

Fishbone Diagram

Man

Methods

PGW associates following proper procedures

Location of defect on windshield

Time length to Auto Clave

Associates trained properly

Sealing Agent

Clipping during ACV

Trimming Process

PGW experience

Ice Flowers

QM data on Pummel, MBH, moisture

Prepress Temp too Low/High

Condition of vinyl at process

Auto Clave Cond-Heat to Low

Auto Clave Cond-cycle time

Paint Surface RZ (glass)

Auto Clave Cond-release temp

Volatile Substance on vinyl

Oven temperature and nipper process

Auto Clave Pressure too Low/High

Material

Machine


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DOE Testing (Design of Experiment)

Snake chart,

tracking material

No issues with flow of material

No significant improvements

No correlation

Japan vs. US vinyl


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Testing

Line process condition changes

Trimming process (Cutting vs. Buffing)

 No significant difference

Lamination oven temperatures (Increasing and decreasing temperature)

 No significant difference

Cure time (24hrs, 48hrs, 72hrs)

 No significant difference

Autoclave release temperature

120°F  100°F

Improvement,

but not good enough


Different models tested and compared

Testing

Different models tested and compared

Model with defect

Model without defect

Clip vs. no-clip

Thickness comparison

Clip effected thickness


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Clipping evaluation

Bending gap at the corner of windshield

Approx. 200μ

  • Clips are commonly used by most windshield makers


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Clipping Evaluation

No change in thickness

Change in thickness


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Recreating an Ice Flower


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Results & Recommendations

  • 10-12 psi clips = severe damage & Ice Flowers

  • 2-4 psi clips = no damage or Ice Flowers

October 2011 – Based on SSA’s testing and recommendations PGW Creighton implemented use of 2-4 psi clips

Vinyl Damage

No Damage or

Air Infiltration

Air Infiltration

Recommended PSI range


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Target

Did we meet our target?

  • Prior to Kaizen

  • 2011 - $300,000 warranty claims

  • After Kaizen

  • 2012 – ZERO ice flowers reported

  • – $0 warranty claims

Our Target

  • Reduce Ice Flowers at PGW Creighton by 90% and limit warranty claims to $30,000 in 2012

24% INCREASE

SSA very

Happy!

2012

Revised

budget

Customer very Happy!

2012

original

budget

2012

Original

budget

2011


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Standardization

Share information with all customers

Future Plans

Share information globally with all Sekisui colleagues


Questions

October 19th 2012

Questions?

The Eliminators

Vince Taylor

Kristie Jones

David Thomas

SEKISUI S-LEC AMERICA,LLC

Technical Service Team

Presenting for the 2012 Kaizen Competition


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