qcc品管圈ppt课件.pptx

3.TBR Tire Manufacture ProcessDMAICExtrudingTop TreadSidewallCushionTop TreadBeltIL CalenderingILCuringBEAD、HSBBead StiffnerShapingTurn UpBeadPlyBeltW-CHCoating Cutting CushionPlyW.chN.chILsidewallN-CH4/284-1.Background Of KaizenDMAICProduction ticket can not be achieved due to building loss.Waiting for No.2/3 belt was main cause of production loss!5/284-2.Background Of KaizenDMAICNo.1 Belt Cutting Machine6/285.Definition Of Roll AdhesionDMAIC123/286. Consequence Of Roll AdhesionDMAICDeposition of roll adhesion(TS)Roll adhesion urgently needs Kaizen!①Get rid of sticky rubber②Sheet up the stocked rubberFrontBackThe deposition need total about 20Min.5min7min③Reload and guide sheet④Joint and reapply sheetFrontFront3min5minCOPQ·Average production loss 815Pcs/Mon ( Jan and Feb)·Loss of conversion cost:300,000RMB/Month/288.Set Up Target DMAIC·The Current State·The Ideal State Current Order : 3600Pcs/dayLine speed : 260rpm220rpm Maximum MTP : 5180Pcs/dayLine speed : 370rpmSet up targetHugeGapRoll adhesion ZDLine speed reach 400rpm/289-1. Analysis-4MDMAIC·Calender machine·OperatorsItemResultSpecificationJudgementCooling capacityTemp. conform to settingConforming to settingOKThe cooling pipe jamFlowing freelyFlowing freelyOKRolls gear ratio1 : 1 : 11 : 1 : 1OK……OKNot Found Gap. ·Process·MaterialOK/289-2.VOC of GenbaDMAIC The voices of No.1 Belt cutting machine operators:Higher Speed(81.8%)220rpm High temperature of No.2 roll might cause roll adhesion./2810.CFT Improvement Analysis DMAIC/2811-1.Analysis Of No.2 RollDMAIC(2) Roll Temp. Setting Kaizen(1) Roll Surface KaizenSurface become too smooth SPEC:60℃270rpmTemp. setting can not be lowered in further due to machine capacity.Speed is improved to 250rpmSpeed is improved to 270rpm/2811-2.G466 Compound AdjustmentDMAIC①. Evaluated Items:TA39 replace to TE29①.G′②.TS2.0③.MT1④.MT2⑤.Sp.Gr⑥.BP⑦.VD⑧.SLAB·Over all evaluated items within Spec. (Recipe Adjustment: Cost down:1,000,000RMB/year)②.Recipe Review:Line speed can reach to