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Manufacturing 327

Phase II. Manufacturing 327. Team: SafeKrackers Associate Name E-Mail Address Position Tracy D. Hille tracyh@epicturbo.com Sr. Program Engr. George Pucci gpucci@lear.com Facilities Mgr. Mike Wheeler mwheeler@wollin.com Process Engr.

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Manufacturing 327

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  1. Phase II Manufacturing 327 Team: SafeKrackers Associate Name E-Mail Address Position Tracy D. Hille tracyh@epicturbo.comSr. Program Engr. George Pucci gpucci@lear.comFacilities Mgr. Mike Wheeler mwheeler@wollin.comProcess Engr. John Reddaway John.reddaway@tenneco-automotive.com Tech. Support Engr. Tim McIlrath Tim.mcilrath@tenneco-automotive.comSr. Design Engr. Eric Everman eeverman@lear.comQ.A. Engr. Slides will advance automatically

  2. Problem Statement • The number one field failure is related to the servo drive shaft coupler that connects the programmable servomotor to the vault combination knob.

  3. Project Objective • Develop Core Team. • Analyze Field Failures. • Determine Defective Coupler Cause. • Reevaluate Coupling Design. • Cost Analysis of Redesigned Coupling. • Implementation of New Couplings.

  4. Performance – Pareto Chart

  5. Finite Element Analysis - FEA Tension Torsion

  6. FEA – Red Stress Areas Tension Torsion

  7. Irreversible Corrective Action • Maintain Correct Rib Thickness (SPC Analysis Performed On-Line). • Radius Relief End of Each Slot (CNC Program Enhanced).

  8. Corrective Action Cost Analysis • Cycle Time - Original 5.04 minutes = $2.21 - New 5.34 minutes = $2.34 • Add SPC Analysis. • Reduce Cutter Life • Scale Back Final Torque Test from 100% to AQL.

  9. How To - Long Form SafeKrackers Long Form is broken down into four sections: 1 – Introduction 2 – Appendix A (SDA’s) 3 – Appendix B (RCA’s) 4 – Bibliography

  10. Long Form - Introduction The Introduction has links imbedded into the document. Simply mouse click on a blue link to jump to the corresponding form in the appendix. Press the blue arrow at the top of the page to jump back to the introduction.

  11. Long Form - Introduction The introduction details overviews of the Company, Customer, Product, Quality, and Process. It also details the Slot Cutting Process, along with Additional Process Improvements.

  12. Long Form – Appendix A This section includes all forms used during the objective of the project. These are referred to as Standard Dedicated Applications – SDA’s You will find them in the following order: Safety, Quality, Process, Finance, Planning.

  13. Long Form – Appendix B This section includes additional information gathered during the project. These are referred to as Regular Critique Assignments – RCA’s. RCA’s include: additional reading sources, team assessments, rotational matrix, and management review.

  14. Long Form – Bibliography This section details all sources used during the project.

  15. Company Goal Advance Relentlessly

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