Decreasing the scrap level for broken/damaged thread

- ALL PROJECTS-
TRW Roman
 DMAIC Define
Business Case and Project Goal:

WHAT : Decrease the scrap level for Damaged thread/Broken Thread Reject level (Lines reject)
WHY : Damaged thread and Broken thread - 90365 parts out of 243767 NOK (9803664 total parts) produced in all
production lines between CW01-CW25. => 0.92% from 2.49%.
Scrap Reduction/ decreasing level of waste from 90365 parts / 0.92% (~270000 €) to 60000 parts / 0.60% (~180000 €) , estimated

CW25 ÷ CW31

Start: 15/06/2016 (CW 25) CW32 ÷ CW37

WHEN :
Stop: 09/12/2016 (CW 49) CW38 ÷ CW40

CW41 ÷ CW44

CW45 ÷ CW49
WHERE : ZF TRW ROMAN

WHO :Team members:

HOW : Includes: Defective parts produced in lines , scrap percentage due to change over , scrap percentage resulted
from over time;
Excludes: Direct Material (handling and preparing the material outside the line), energetic consumption. •Quality Engineer
Expected Business Results: •Maintenance
• Reducing scrap rate on plant level with 0.3% (from 2.49% to 2.18%) •Production Supervisor
• Improve OEE (plant level)
• Reducing costs based on quantity of rejected parts •Manufacturing Engineer
• Reduce number of projects in DLN control
• Process stabilization
6/13/2019
Annex. 1 Business unit, Presentation title
DMAIC Measure
Data Collection Plan
What is the main contributor to the scrap level on the line?

Data to be collected Operational Definition and Procedures

-All defects produced in line How
-Presence of operators in line
3 shifts collection  hourly verifications per shift
(actual vs. standard) Data collection on Fiat 334.520TAB -
-All anomalies at working performed exclusively by
pilot lines: 11 manuals (seam 301 +
Production Leader
stations 19.09 - 30.09.2015 4 automatic + 1 control
station.  Collection split by
3 shifts collection automatic/manual
GM D2XX TAB - machine and 6M.
5 manuals (seam 401 +  Data analyzed by QE.
3 automatic + 1 control
station.

Consistency and stability of the data collected will Production Leader will include all defects. All defects included
be ensured by Production Leader. into analyze will be recorded on boards available near the production
line.

Pareto analyze of the data

13 June 2019 Business unit, Presentation title

 DMAIC Measure
Nonconformities identified in production lines FIAT 334/520 TAB si GM D2XX TAB (pilot programs)
1.Diferent sewing program speed on same operation , on different automatic machines.

2.Existance of other sewing programs than standard (needed).

3.Oiling system not known (maintenance level 1 not fully effective) – greifer part

4.Preventive maintenance instructions level 1 incomplete defined (oiling point for greifer is not defined for automatic machines)

5.Oiling system was not performed at reception of the machines in production area.

6.MTM2 not known by PL.

7.Errors in MTM2 studies on server or are hard to respect/follow.

8.Errors in correct report for defect codes (replacement of some defect codes with other defect codes).

Preliminary Action Plan :

• Standardize sewing speed on all automatic machines form production lines to 1400 rot /min(FIAT 334.520 TAB si GM D2XX TAB) – 10.08.2016 - DONE
• Standardize sewing speed : low speed -140 si mid speed 1200 on all automatic machines(S-AM36/003/005/006 si S-AM36/0010/0015/0007) – 10.08.2016 - DONE
• Delete all existing additional sewing programs from automatic machines–10.08.2016 DONE
• Training for all operators in line about all oiling points (maintenance level 1) – 12.08.2016 DONE
• Oiling system (manual machines/automatic machines) –13.08.2016 – DONE
• Update MTM2 Study for Fiat 334/520 TAB – 19.08.2016 –done and GM D2XX TAB – 10.08.2016 DONE
• Training for PL regarding updated balancing of the lines – 22.08.2016 – done
• Monitor/comparison of accuracy about reporting the scrapped parts on shifts (pilot lines Fiat 356 TAB) – 19.08.2016 - done

13 June 2019 Business unit, Presentation title

DMAIC Analyze
• 6M for Broken Thread on pilot lines. GM D2XX TAB Fiat 334.520TAB

Business unit, Presentation title

13 June 2019
 Root
Man
Cause Analysis for automatic/manual
Milieu
Machine
machines
Qualification Training
Storage condition for thread

Training on the job – operational criteria for Charging device for lower bobbin not
automatic machines not fully known working properly

Absenteeism – operators are pushed to cover lack Lower bobbin brake not fully effective
of personnel

Presser foot not protected against hitting with the

sewing frames

Broken thread
Workload not respected in production line (MTM2
Thread not known/respected
Blunted needles

Sewing speed not standardize

Low length of thread after cutting is
performed (for automatic machines)
Incomplete instructions for maintenance level 1

Rule for changing needle not fully effective

Missing point in handover checklist about oiling

system Main Root cause

Secondary
Preventive Maintenance level 1,2 and 3 Root cause
Material not performed
Method Tools

6/13/2019
 DMAIC Analyze
After Measure step, a structured list of possible solutions to each specific problem identified is shown below:

Machine
• Depreciated Equipment
- The charging system for lower bobbin are not efficient. The lower bobbin are not charged as it should (lower quantity of thread/incorrect weaving thread
load).
• Incorrect cut of the thread length after finish sewing (manual machine 301 seam) => first sewing steps, at seam start, are often skipped (not tangled).
• Inappropriate changing needle rule in case of seams with long backstitch. (Higher needle usage)
• Lower bobbin brake system not fully effective (for automatic machines). Inertia impact.
• Presser foot and needle not protected against contact with sewing frames ( automatic machines). 7 interventions in 4 weeks on pilot projects and 128
interventions in 11 weeks – plant level.

Man
• Lack of triggering signal for changing the lower bobbin when thread is finished (manual machine – seam 301)
• Movement of the operators between stations, without being confirmed on operation (Qualification Matrix not followed).
• High absenteeism.
•Training on the job not fully defined and with minimum supervision.

Material
• Thread (many times deteriorated thread defect is being removed only by changing the thread bobbin).

Methods
• MTM 2 studies not respected/not known in production lines.(Skipping work elements due to less operators than standard - ME defined).
• Oiling system not taken into consideration at reception of the machines –manual and automatic - (oiling system is empty).
• Maintenance level 1 instructions incomplete – E.g. 3 out of 4 oiling points specified in instruction.
• Preventive and predictive maintenance not planned nor performed for pilot production lines.
13 June 2019 Business unit, Presentation title
DMAIC Improve
Action to be implemented at plant level
1. Revision for all charging system for lower bobbin (manual/automatic machines) –24.12.2016.
2. Implement counter for number of stitch for seam 301 (manual machines) – 24.12.2016
Actual – implemented on 57 manual machines (only for thorax projects)
To be performed – KAB (34 manual machines) / DAB (19 manual machines) / PAB (21 manual machines) and on 7 manual machines from TAB Projects
3. Implement presser foot / needle protection for all automatic machines ( 134 machines) 01.01.2017
4. Update maintenance level 1 instructions in order to specify all oiling points on automatic machines –24.12.2016
5. Preload /Refill all oil tanks for automatic/manual machines –24.12.2016
6. Training for all production leaders to apply line balancing according to MTM2 in case of lack of personnel –01.01.2017
7. Change rule for changing period of the needle when existing long backstitches (ex: Fiat 334.520 TAB / PQ25 HTAB / Fiat 356.Alfa 952 TAB / Alfa 949 NAFTA
TAB ) 24.12.2016
8. Implement 1 small stitch on automatic machines from sewing program for staple seam , unload seam , tear seam , standard seam .
9. Update checklist at machine handover to production area for preload/fill oil tanks/system for manual/automatic machines 24.12.2016
10.Implement retaining clip for length of thread after cutting is performed (between sewing steps).
Risks :
- Implementation of counter for manual machines without an effective training and without supervision ,will conduct to higher scrap rate and not to use this
counter properly in the future.

13 June 2019 Business unit, Presentation title

DMAIC Improve
• Lower bobbin incorect loaded on automatic and manual machines – loading system for lower bobbin is not working properly due to
usage and not systematically maintained. The lower bobbin is incomplete loaded or loaded with more thread than needed (operators
need to help the loading system with hand for complete load – foto. 3). The winding of thread on lower bobbin is not uniform.
Foto 3

During measure period 47 parts (~15%) out of 317 parts with defect broken thread were produced due to incorrect
loaded lower bobbin (cause analyzed by production leader).

13 June 2019 Business unit, Presentation title

DMAIC Improve
• Setting a predefined number of bags wich can be sewn with one bobin for manual machines – seam 301;
- Implement counter for number of stitch which can be sewn with one bobbin (manual machine will be automatically blocked when thenumber of stitch are
reached) ; Risk identified: Very important is the training of operators for correct usage of this counter.

Stitch number for number of bags on lower bobbin

Fiat 334.520 TAB

Visual aid when stitch are over (last bag

in progress to be sewn)

1.At the last bag sewn , the machine will stop while sewing and light bulbs will turn ON.
The seam can be performed forward until the thread is cut. Machine will not start sewing , after last thread cut .
2.The machine will start sew again after the lower bobbin are changed and reset the counter
(with “8” function code from controller / display).
13 June 2019 Business unit, Presentation title
DMAIC Improve
• Implement presser foot / needle protection for automatic machines

Before After

Presser foot protected

No. of intervention for presser foot damaged/hit :

Presser foot can be damaged
during sewing frames handling
13 June 2019
*7 interventions in 4 weeks on pilot projects
*128 interventions in 11 weeks on plant level
Business unit, Presentation title
DMAIC Improve
• Update maintenance level 1 instructions in order to specify all oiling points on automatic machines

Area for refill the

oiling system

Display

Area for checking the oil level.

Not specified in maintenance level 1 instructions

13 June 2019 Business unit, Presentation title

DMAIC Improve
• Update reception instruction (add point in checklist) for checking/completition of oiling system for manual/automatic machines

Oil tank

At machines receptions , cotton wires are Need to be oiled and

not immersed for lube system introduced in oil tank

13 June 2019 Business unit, Presentation title

 DMAIC Improve
• Define and aply diferent line balancing, in case of lack of personnel ;
- The scope is that all predefined work elements to be performed accurately according Process definition. By overloading the operators, risk for errors is
increasing
- Actual status: self balanncing, in case of not standard number of operators in production lines.

• Production date : 10.10.2016 – shift 2 – 14 operators actual / 17 operators standard – balancing not folowed according to MTM2
Available Target Availability Performanc Quality
Bag Type Project name PN Planificat Target Std time Target Std pcs/min OK NOK Scrap[%] OEE
time recalc (%) e (%) Rate(%)
HTAB PQ 12 HTAB 640 750 450 400 750 0.6 526 666.6667 22 4.01% 88.89% 82.20% 96.0% 70%

• Production date : 11.10.2016 – shift 2 – 13 operators actual (same operators !) / 17 operators standard – balancing performed according to MTM2
Available Target Availability Performanc Quality
Bag Type Project name PN Planificat Target Std time Target Std pcs/min OK NOK Scrap[%] OEE
time recalc (%) e (%) Rate(%)
HTAB PQ 12 HTAB 640 750 450 405 750 0.6 589 675 8 1.34% 90.00% 88.44% 98.7% 79%

Action implemented:
• Line balaced for 14 operators
• Comunication to operators of reviewed quantity to be produced in 14 operators

• Advantages : Lower Scrap level / Stability / Operators performs less operation and only what they are trainned for.

13 June 2019 Business unit, Presentation title

DMAIC Improve
• Oiling system was preloaded (automatic machines) and oil tank was refilled (for manual machines);

• For manual machines (seam 301) the needles have been changed once per 3 shifts instead of 6 shifts.

Fiat 334.520 TAB

• -Results for damaged thread:

13 June 2019 Business unit, Presentation title

DMAIC Improve
• Implement one small step at seam start Before

END seam

Initial view of the seam (steps have

the same length)

First steps are not caught – lower

STARTseam thread is not caught

After

1 small step have been added

6/13/2019 Business unit, Presentation title

DMAIC Improve
• Setting a predefined number of stitch at seam start (for seam 301) with low speed – slow start;

• - The scope is to eliminate the risk that the lower thread not be catched by the upper thread at first 10 stitches (at start of sewing process).
Results not available yet. Monitoring 13.10.2016 2nd shift to 21.10.2016 3rd shift

Action implemented on 1 manual machine(PQ25 HTAB) on 13.10.2016 1st shift

NOT confirmed

Seam start
First 5 stitches will have slow start from machine settings

13 June 2019 Business unit, Presentation title

 DMAIC Improve
• Implement retaining clip for length of thread after cutting is performed (between sewing steps).
• - The scope is to eliminate the risk that the lower thread not be catched by the upper thread at first stitches (at start of sewing process).
Before

After

Retaining clip

13 June 2019 Business unit, Presentation title

 DMAIC Improve
• Result after improve actions for pilot lines

• -oiling system for automatic and manual machine - hourly checking for scrapped parts (performed by PL)

• -implement number of stitch for 301 seam - replace lower bobbin brake for automatic machine (S-AM21-0002)
GM D2XX TAB Fiat 334.520 TAB