Green Belt Project Reduce Process Wire Loss on Stator Manufacturing

Project Leader: Rowena Weichmann Champion: Craig Schlau Team Members: Paul Goldsmith : Set Up Rick Walden : Manufacturing Engineer Group Leader Leonard Carriero : Process Engineer Mike Holland : Production Operator Terry Buck : Production Operator Keith Gildner : Production Supervisor

June October 2007

October 31,2007

Define

Reduce Process Wire Loss from Stator Manufacturing

Project IPO Diagram

People Methods Materials Process Variables Measurement Stator

Reduce Variation

Performance

Time

INPUTS

PROCESS

OUTPUTS

Define

Reduce Process Wire Loss from Stator Manufacturing by $50,000 a Year

Measure

How much waste is there?

Measure - What We Did

30 Pc. Studies of how much wire was being cut off each winder Find out how many stators are produced each year off each winder Find out what stators are being run on what machines Find out what wire is in each model of stator being produced Convert inches to feet Convert feet to pounds $ Value for each wire

Measure

How much waste is there?

Maximum Potential Savings of Waste Wire Waste $45,000 $40,000 $35,000 $30,000 $25,000 $20,000 $15,000 $10,000 $5,000 $Large Stack Stators (4000) 8LHA Stators Brushless Stators SC Stators Small Stack Stators
40,763 31,417 15,055 9,998 3,230 230

Medium Stack Stators

Large Stack Stators (4000) 8LHA Stators Brushless Stators SC Stators Small Stack Stators (2500) Medium Stack Stators (Hvy Std)

$ $ $ $ $ $

TOTAL $

100,693

Analyze

Cause & Effect

Machine How is winder set up Tension No controls for lead lengths

People No Set Up Instructions Not setting up the same from set up to set up Not setting up the same from shift to shift

How do we measure What do we measure with We do not measure lead length Methods Materials

What We Did
Had 30 pc. runs on different lead lengths Followed through to end of line for any problems Worked with operators on shorter leads Offered tools to help Decided on correct lead lengths that didnt cause problems at following operations

Improve & Control

Before No Set Up Instructions No Specs. for Lead Lengths Nothing Being Recorded

After Set Up Instructions for Winders Spec. for Start & Finish Leads Spec. for Wind Diameter Set Up Log to Record Lead Lengths & Wind Diameter Stop Blocks & Set Up Blocks to Assist in Set Up 6 Scale for Measuring Lead Lengths Cloth Measuring Tape for Measuring Wind Diameter Reference Gage-After Inserting Update Standard Operating Procedures Update Control Plan Revise B.O.M.

Results

Wire Waste
$45,000 $40,000 $35,000 $30,000 $25,000 $20,000 $15,000 $10,000 $5,000 $Large Stack Stators (4000) 8LHA Stators Brushless Stators SC Stators Small Stack Stators (2500) Medium Stack Stators (Hvy Std) Before Savings After

Before
Large Stack Stators (4000) 8LHA Stators Brushless Stators SC Stators Small Stack Stators (2500) Medium Stack Stators (Hvy Std) $ $ $ $ $ $ 40,763 31,417 15,055 9,998 3,230 230

Savings
$ $ $ $ $ $ 31,357 18,471 13,958 8,358 1,826 177
$ $ $ $ $ $

After
9,406 12,946 1,097 1,640 1,404 53

TOTAL $ 100,693

$ 74,147 $

26,546