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Kaizen Event : UC Squib Productivity Improvement and

Reduction in Rejection.

Team Leader:Deepak(ME).

Team members: Kiran (Prod), Rajesh (ME), Prasad (Tool Main), Paramesh (Prod)

Date : 18th March 2010

page 2

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Base line

Metric Baseline Target Improvement

Cycle Time 54 sec 40 sec 26%

Rejection percentage 12% 4% 67%

Mold down time 6.3 hrs/month 1 hr/month 84%

page 3

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PRODUCT OVER VIEW

UC squib is used in air bag application. It is used for secure connection of the airbag ignitor via the cable harness to the airbag control box. We produce around 39 pn according to different lengths and cables.

Customer:- Autoliv,Takata,Filec.

page 4

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Why this project?

• Increase in customer demand.

• The daily machine capacity was 7500nos

• Customer escalation regarding delivery

• High scrap percentage.

page 5

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Pareto Analysis

Rejection reasons Qty Percentage

Material entry 13636 39.81

Flash on cable 4735 13.82

Rough finish 3970 11.59

Flash on contact 3642 10.63

Incoming problem 2969 8.67

Short shot 2584 7.54

Contamination 1343 3.92

Contact visible 726 2.12

Contact height

variation 352 1.03

Cable damage 296 0.86

Pareto for rejection qty

39.81

53.63

65.22

75.8684.52

92.07 95.99 98.11 99.14 100.00

0

2000

4000

6000

8000

10000

12000

14000

16000

Material entry Flash on cable Rough finish Flash on contact Incomingproblem

Short shot Contamination Contact visible Contact heightvariation

Cable damge

Reasons

Qty

0.00

20.00

40.00

60.00

80.00

100.00

120.00

page 6

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Action Plan

Major Problem Causes Corrective action proposedMaterial entry Gap between ferrite and contact.

Narrow process window . Delay in cycles.

Optimizing the cycle time.

By increasing mold open/Close speed,By increasing nozzle advance/retraction speed.Rotary table speed.Adding one more operator station for part removal.

Flash on cable Improper placement.Narrow process window.Imbalance in filling.

Training to operators .

Optimizing the cycle time.

page 7

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Action Plan

Major Problem Causes Corrective action proposed

Rough finish

DroolingDelay in cycle

Narrow process window.

Imbalance in filling.

Optimizing the cycle time

Flash on contact Delay in cycle

Narrow process window.

Imbalance in filling.

Optimizing the cycle time

page 8

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Action plan

Burn mark

No air vents

Air vents provided

Before After Before After

Cable insertionNozzle Retraction speed (%):-25Nozzle retract stroke(mm):260Delay time (sec):-15

Nozzle retraction

Nozzle Retraction speed (%):-40Nozzle retract stoke(mm):223Delay time (sec):-2

Speed(%):-35Rotary table movement

Speed(%):-50 Opening speed(%):15/40/20 Mold opening Opening speed(%):15/40/20

Closing speed(%):15/20/15

Mold closingClosing speed(%):35/45/15

Speed(%):-35Rotary table movement

Speed(%):-50

Nozzle advance speed (%):-50/15

Nozzle advanceNozzle advance speed (%):-50/15

Cable removal

Injection

page 9

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Action Plan

• One more stage for manpower added for part removal and insertion

instead of one person doing it.

• Training for all UC Squib operators as per WI.

Before After

page 10

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Benefits

• Productivity Improvement.

• Efficiency improvement

• Improvement in mold down time

84% .

Daily output

9065

12545

0

2000

4000

6000

8000

10000

12000

14000

Before After

Qty

Efficiency

155

110127

138

0

20

40

60

80

100

120

140

160

180

November December January Febraury

Month

Eff

page 11

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Benifits

Rej PPM

9 0 3 3 2

3 8 2 553 4 571

4 2 72 1

0

10000

20000

30000

40000

50000

60000

70000

80000

90000

100000

November December January FebruaryMonth

PP

M• Reduction in rejection.

• Mold down time reduced from 6.3 hrs to 1 hr.

page 12

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Benefits and Next Action Plan

Savings ($) December January February

3547 4038 4446

Next Action Plans

• Replacing the injection unit with nozzle shut of unit.

• Working on Visual inspection stages .

page 13

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Thank you