Transcript No Slide Title

I&CIM Project – Study
Project:Study
Date Opened: April 3, 200x
I&CIM Contact: Jim Altier
Project Sponsor:
Problem Definition
As a follow up to the Wafer study that was complete in
November 200x, the tooling was evaluated another
Source of excessive downtime.
Project Scope
Xxxxxx tooling breakage on the xxx series xxx parts
Stamping Die’s causing production scrap parts, press
down time and increased tooling cost. Plant x
production presses.
Customer: Plant Manufacturing & Plant Assembly
Project status: Closed
Detail No. Used (4/1/02 - 3/31/03)
8GAB436 238 (152 + 86 EXP's)
Detail Cost
$46.32
Total Cost
$11,024
8GBN996
183
$95.09
$17,401
8GAD977
16
$88.14
$1,410
8GAD976
16
$88.28
$1,412
8GAD974
4
$155.72
$622
8GAD973
15
$134.85
$2,022
8GBNE75
9
$199.83
$1,798
8GBNE72
15
$164.70
$2,470
8GBNE71
8
$212.21
$1,697
Implement improvements
Per suggestion # XX-xxxxx the detail was revised to remove the
Sharp corners but maintain the material type, carbide. In the
Process of changing detail number 8xxxxx (lower emboss) a
redesign on the upper was also evaluated. By changing the upper
detail (8xxxxx), die holders were eliminated from the die.
The average life of the 8xxxxx is now 14,500,00 as opposed
to 4,236,689 pieces and the 8xxxxx is now 25,000,000 as
opposed to 5,510,000.
Control and Maintain
Tool detail drawings changed to reflect the new detail design.
Preventative maintenance instructions changed to reflect that the
details need to be inspected prior to being replaced due to extended
life of the new parts.
No. Dies
3
2
4
2
3
2
4
2
1
2
1
2
1
1
1
1
1
2
1
1
1
2
1
1
Location
Bottom
Bottom
Bottom
Bottom
Top
Top
Top
Top
Bottom
Bottom
Bottom
Bottom
Bottom
Bottom
Bottom
Bottom
Top
Top
Top
Top
Top
Top
Top
Top
Quantity In Die
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
Emboss Tooling Check
Sheet
Production (4/1/02 - 3/31/03)
1,008,332,000
Where we were!
Characterize Current State/ID failure modes
Current detail design has sharp corners in the area where detail
strikes the stock. The theory is that the sharp corners reduce the
life of the detail. Consequently, details are changed often,
reduce uptime and cause scrap. Detail usage versus accumulated
production indicates that life is 4,236,689 pieces per detail.
Die
12193800
12193802
12193808
12193810
12193800
12193802
12193808
12193810
15329083
15356861
15329083
15356861
15329084
15356862
15329084
15356862
15329083
15356861
15329084
15356862
15329083
15356861
15329084
15356862
Press:
Date:
1,008,332,000
405
________
Data collection
Time:
137,618,000
________ AM / PM
Please circle which piece of tooling is
being changed.
137,618,000
76,445,000
No need for worn or broken details at
this time.
Top
Bottom
View
View
of
of
Emb
Embos
oss
s
Tooli
Toolin
ng
g
76,445,000
137,618,000
1,222,395,000
76,445,000
BEC Emboss Study
Potential Savings on 2004 Volume
Detail
8GAB436
Detail
8GBN966
Condition Average
Current
Proposed
Condition Average
Current
Proposed
(product ion per det ail)
2004 Volume
4,236,689
14,500,000
864,454,872
Details Needed Cost per Detail Cost per Year
204
$
46.00 $
9,386
60
$
148.00 $
8,823
$
562
Details Needed Cost per Detail Cost per Year
157
$
96.00 $
15,061
35
$
100.00 $
3,458
$
11,603
Details Eliminated by Improvement (Die Holders)
Details
Used (2003)
Cost per Detail
Total Cost
8GAY083
1
$
146.00 $
146.00
8GAY084
18
$
130.00 $ 2,340.00
8GAY091
1
$
152.00 $
152.00
8GAY092
22
$
165.00 $ 3,630.00
$ 6,268.00
$
6,268
(product ion per det ail)
Savings
2004 Volume
5,510,010
25,000,000
864,454,872
Savings
Cost Benefit Analysis
Savings
Scrap Reduction
*Prior to the study, deprtment 1119 averaged 18,000 pcs. per month in Emboss related scrap.
During the study (4 months) there 0 red tags, a scrap reduction of 72,000 pcs.
The project team is estimating a 80% reduction in scrap, this is equal to 57,600 pcs. @ .01 per piece.
72,000 x .80 = 57,600 x .01 = $580.00
$
580
$
19,014
$
$
Bravor
299.00
199.00
Quote Results:
DIME
8GAB436 $
8GBN966 $
86.00
32.00
$
$
Swiss-Craft
140.00
90.00
$
$
CMT
148.00
121.00
$
$
Imperial
155.00
88.00
* The average of Swiss-Craft, CMT and Imperial was used for the cost per detail in the Proposed Improvement.
Delphi Confidential
Page 1
Savings
Total Savings