Campbell Soup

Worked for Sumitomo Electric Wiring Systems for more than 15 years.

Sumitomo Electric is a Japanese Automotive OEM Tier 1 supplier.

Main Customers:• Honda

• Toyota

• GM

• NissanProducts:

• Fuse Boxes

• ECU’s

• Center Cluster Modules

• Wiring Harnesses

Situation:• Received a claim from our customer for a bent tab.

Obstacles:• Our current process did not confirm conductivity of certain circuits that are routed through the ECU using a end of line circuit testing program, due to proprietary programming and schematic information that the tier 2 supplier would not release.

• The current probe block design allowed the probes to move up and down which would change the amount of compression needed to pass each circuit.

Actions:• Conceived, directed and oversaw the implementation of a new probe assembly.

Results:• Prior to May of 2008 this machine had an average of 32 minutes downtime per week due to probe issues. Since then there has been no recorded downtime due to this.

• Output was increased by 75 parts per week.

• Most importantly, no claims have been issued by the customer.

Probe Test Block Re-design

Lower probes have dropped and now are very close to the bottom of the connector cavity.

1mm space between upper and lower probes.

If the Upper Probes drop down, then the gap becomes smaller and the risk of flow-out increases.

Original Common JB Case Lock Tab Check Fixture. (Shown with probes lowered inside of connector pocket).

Bottom of Connector Cavity

Pre-existing Design

Illustration of how the part could have passed the Case Lock Machine.

Terminal Missing causing bump

Pre-existing Design

Add 1mm to the spacer height.

Temporary Countermeasure

Spacer change to 21mm.

2mm space between upper and lower probes.

Added Spacer in Defect Sample to ensure probes would be compressed during daily checks.

Temporary Countermeasure

Not Engaged.

Permanent Countermeasure – New Design

Engaged.

Permanent Countermeasure – New Design

Permanent Countermeasure – New Design

Situation:• Recurring issue of two tabs being inserted into one socket of the ECU.

Obstacles:• We could not confirm conductivity of the circuits using a end of line circuit testing program, due to proprietary programming and schematic information that the tier 2 supplier would not release.

•The current design would not separate two terminals that are too close together.

Actions:• Designed a new comb assembly which separates the ECU tabs.

Results:• This modification has resulted in increased productivity, reduced scrap, and IPD.

• It has also significantly reduced/eliminated defect flow-out to the customer.

• No additional claims have been issued.

ECU Attachment Improvement

The original comb was 3mm inheight at the face. It entered horizontally from the side and

then was lifted up 3mm.

Original comb wouldhave captured both

tabs in the same cavity.

Raked teeth of combengages the bottomof the tabs as it movesinto position which separates the teeth as the comb enters.

Direction ofcomb travel

New Comb is 16mmIn height at the face.No lift is necessary.

New comb designstraightened the tabs

and holds in placefor ECU engagement.

New design comb engaged on bent tabs shown in previous slide.

N/G Alignment Sensordetects a gap if comb isdepressed by bent tabs.

The N/G Alignmentsensor detects thisgap and causes a fault to display on the operator screen.

The N/G Sample causes the comb to be

pushed back on the spring loaded

mounting shaft.

Situation:•Customer requirements dictated implementation of new terminal insertion process.

Obstacles:•No one within my company had any previous knowledge of this process.

Actions:•Contracted with experienced machine supplier to learn process and to gain knowledge of potential failure modes for transfer to our factory.

•Addressed key mechanical concerns to ensure a stable process was implemented in our factory.

•Trained associates in QA, Engineering, Maintenance, and Manufacturing.

Results:•Able to learn the critical design and process characteristics of the insertion process and pass this knowledge on to QA, Maintenance and Manufacturing.

•Process was implemented successfully for multiple projects and start-up timing was met for all.

Terminal Insertion Process Development

Completed PCB with “Press Fit” terminals which are inserted into the circuit board using a mechanical fit to secure the terminal into position prior to the soldering process.

Completed Fuse Box with completed PCB inside and fuses installed.

Tuning Fork Terminal

PCBCopper Plated Through-hole

Mechanical Concerns:

•Cross corner dimension of the terminal tail is critical to ensure product quality.

•Implemented quality control to ensure terminal were within proper specification prior to shipment.

Terminal Tail

A A

Section A-A

How to Control:

•A logical method would be to simply measure the two sides and calculate the cross corner dimension, or hypotenuse.

•However, this method is not accurate enough due the stamping process of the terminal.

Theoretical Actual

SPEC

Terminal "A" (Inches) GO NO-GO

8-00-11101.5 mm Pin

.0655±.001[1.66±0.025]

0.0665[1.69]

0.0645[1.64]

7-V1028-050AAFuse Terminal

.0580±.0015[1.47±0.04]

0.0595[1.51]

0.0565[1.44]

7-V1030-002AA2.8 mm Blade

.0580±.0015[1.47±0.04]

0.0595[1.51]

0.0565[1.44]

GAGE HOLE DIA.

Use of GO and NO GO Gages

Situation:•Received claim from customer for spread terminal.

Obstacles:•Existing design could not distinguish between each tab during the check process and could not provide feedback on spread terminal or closed terminal.

Actions:•Worked with machine vendor to conceptualize, design and manage a re-design during the sourcing of new assembly line for new GM project.

Results:•Implemented the new design and also utilized this design on future GM projects.

•This design is recognized within the plant as the most reliable and provides the proper feedback to enable the operators to make proper judgment without incurring unnecessary scrap.

Slit Checker Machine Re-design

Pre-Engagement of Part

Engagement to Good Part

Engagement to Bad Part

New Design with Laser

Situation:•Needed to develop quick change tool set to reduce floor space, reduce cost and provide for inexpensive future project development.

Obstacles:•Lack of floor space in clean room and desire to reduce operator walking due to multiple machines.

Actions:•Worked with machine vendor to conceptualize, design and manage the equipment development to our specifications for new GM project.

Results:•Goal of Five minute changeover per machine achieved.

•Operators able to make the changeover thus freeing up valuable Maintenance time and working toward a TPM mentality.

Quick Change Tooling Development

Thank You!