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AP5 Lean Manufacturing Broken Capillary Tubes
Team Members:
Blake Samic
Brent Adams
Dan Healy
Chris Kantus
Chad Linville
Aaron Frees
Advocacy Team:
Kyle Minnick - Mentor
Thiago Tognetti- Mentor
Rob Willy - Mentor
AP4/5 Lean Manufacturing Team
April 26, 2004
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AP5 Lean Manufacturing Broken Capillary Tubes
AP5 Capillary Tube
Scrap Reduction
AP4/5 Lean Manufacturing Team
April 26, 2004
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AP5 Lean Manufacturing Broken Capillary Tubes
Problem Area
Refrigerator
Inside Case
Smaller capillary tube
is still clearly attached
to the large tube
assembly.
Outside Case
Capillary tube is no
longer visible outside
of the case, indicating
that it has been
broken off at the
entrance to the cas.
AP4/5 Lean Manufacturing Team
April 26, 2004
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AP5 Lean Manufacturing Broken Capillary Tubes
Possible Root Causes
•Excessive bending of capillary tube during production
•Many stations bend tube multiple times
•May strain material, causing breakage further down the line
•Missing/Misplaced protective tape on tube
•Unprotected tube rubs on raw edge of case back
•Rubbing may score tube, causing breakage
•Reuse of salvaged capillary tube assemblies
•Rerun tube undergoes more bending than normal
•Holes in assembly at liner drop
•Capillary can become hung up in holes causing severe scoring of the capillary
tube
AP4/5 Lean Manufacturing Team
April 26, 2004
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AP5 Lean Manufacturing Broken Capillary Tubes
Freezer Liner
Formation
Plastic liner to which
cap tube will be
assembled is formed.
Capillary Tube
from Supplier
Process Flow
Hole in conveyor identified as
definite contributor to broken
tubes.
Reuse of capillary tubes of scrapped freezer liners identified as
possible secondary cause. Reused tubes are currently being tagged
to help identify whether this is a contributor to the issue.
Case Line
Capillary Tube is
attached to the formed
plastic liner.
Capillary Tube is
attached to the formed
plastic liner.
Tube arrives from
outsourced supplier.
Possible poor tube design
identified by PMQ could be
contributing to broken tubes.
Assembly
Ends of capillary tube assembly
are brazed to the evaporator and
hi side assembly.
AP4/5 Lean Manufacturing Team
April 26, 2004
Capillary Tube is
foamed into the
finished case making
it impossible to easily
replace.
Capillary Tube is
attached to the formed
plastic liner.
Repair
Somewhere in assmebly
the broken capillary tube
is identified by a worker
and marked out for
repair.
Somewhere in assmebly
the broken capillary tube
is identified by a worker
and marked out for
repair.
Testing and
Packaging
Refrigerators are
scrapped at repair
and never make it to
test and pack.
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AP5 Lean Manufacturing Broken Capillary Tubes
Financial / Business Benefits
Hard Benefits
• Elimination of 3 or more scrapped units per week ($45,000/Yr)
•Elimination of 3 scrapped units per week
($45,000/Yr)
Soft Benefits
• Labor reduction
•Labor
reduction
• Less
rework
and salvage time with scrapped units
• Fewer salvaged parts returned to line
•Less rework and salvage time with scrapped units
•Fewer salvaged parts returned to the line
AP4/5 Lean Manufacturing Team
April 26, 2004
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AP5 Lean Manufacturing Broken Capillary Tubes
Actions
•Identified hole in the case assembly line were capillary tubes
were becoming snagged and scored. Hole was temporarily
covered by Case Line BTL Kyle Minnick and in long term the
hole will be permantently bolted shut.
•All rerun capillary tubes off of scrapped liners are being marked
in or to discern whether the rerunning of these tubes is
contributing to the issue
Note: After covering the hole on the assembly line no broken capillary tubes were seen for
a week and a half. A few were seen at the end of last week but we are unsure if these
breaks are caused by the same one that has been causing the three or so a week. None of
the units with broken tubes have yet to be from a rerun tube off of a bad liner.
AP4/5 Lean Manufacturing Team
April 26, 2004
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AP5 Lean Manufacturing Broken Capillary Tubes
Current:
••3On
average
units
a week 3areorscrapped
due to broken
capillary
more
completed
tubes with
costingare
the
units
per week
business $45,000
annually
scrapped
because
of
broken capillary
tubes.
AP4/5 Lean Manufacturing Team
April 26, 2004
Future:
••Place
Plan metal
to place
slugs in all
metal
slugs
holes on
assembly line
into
assembly
where
the capillary tube
may to
hang
up
line
cover
any
and allof not rerunning
•Possibility
holes
where
capillary
tubes off of
scrapped
tube
mayliners
become
caught.
•No reuse of
capillary tubes
(if long term
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AP5 Lean Manufacturing Broken Capillary Tubes
Capillary Tube Project Contacts
Jay Fields (BTL Case Line)
Kyle Minnick (BTL Case Line)
Gene Pikes (Tech Support Case)
Martin Pike (Inspector Assembly Line)
Larry Byrne (EOLA Technician)
Larry Crouch (Test and Pack Repairman)
Mike Mulcahy (BTL Case Line)
Del Cofield (Blackbelt AP4/5)
AP4/5 Lean Manufacturing Team
April 26, 2004
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AP5 Lean Manufacturing Broken Capillary Tubes
What we gained from our lean experience
learned how to:
•We
C •communicate with individuals out on the floor to work towards a common goal
• •to research an issue of which we had no prior knowledge
• •how to formulate a plan of attack in order to solve the issue
• •work together with teammates on a project that would otherwise be to large and time consuming to
•u
undertake alone.
We learned never to:
• • start investigating an area in a union factory without first consulting the union steward.
• • take pictures of any union personel on the job.
•n• ever to bring a camera, stopwatch, or large group of engineers into an area and start asking questions without
first having the proper meetings with union officials.
AP4/5 Lean Manufacturing Team
April 26, 2004