Assignment 2

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School

Conestoga College *

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8010

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Industrial Engineering

Date

Apr 3, 2024

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Uploaded by SuperHumanCoyotePerson1024

ASSIGNMENT - 02 Project Definition Submitted By: Janam Pareshkumar Patel ID - 8911416 Submitted to: Brendon Pilgrim QUAL8052 – Lean Six Sigma Date : 02/16/2024

1. Problem Statement: • Flight Time Recently installed systems at Laser Inspection Systems are failing at a rate that is higher than acceptable, which has an effect on customer satisfaction and profitability. This issue has been present for the past 12 to 18 months and needs to be addressed right away. 2. Objective Statement: • Reduce the failure rate of Time-of-Flight Laser Inspection Systems by 50% within the next 6 months, as measured by the number of systems returned for repair or replacement. This will improve customer satisfaction and increase profitability. 3. Quality Tools: Issue Number of incidents Laser output low (adjusted on-site) 2 No output 5 Retuned Galvanometers (adjusted on-site) 3 Other 1 Fig 1 Install Issues for October • Fig 1 shows Analysis which indicates that “No Output” account for the majority of field issues.

Time since install Issue Repair action Total time taken (in hours) Less than 1 month Y-Axis Galvanometer not functioning Replace galvanometer and re- test 25 1 to 3 months Y-axis Galvanometer failure Replace galvanometer and re- test 25 3-6 months No output power Replaced laser 25 3-6 months No output power Replaced laser 25 3-6 months No output power Replaced laser 25 6-12 months No output power Replaced laser 25 1 to 3 months Both Galvanometers out of calibration Replace Galvanometers and retest 20 3-6 months Galvanometer out of calibration Retuned control circuit and replaced galvanometer 15 3-6 months No output power Replaced faulty control circuit 15 6-12 months No output power Replaced faulty control circuit 15 Less than 1 month No laser output Replace control board 10 1 to 3 months Power supply short circuit Replaced PSU 10 Less than 1 month X-Axis galvanometer out of calibration Retuned X-galvanometer 5 1 to 3 months X-Axis galvanometer out of calibration Retuned X-galvanometer 5 1 to 3 months X-Axis galvanometer out of calibration Retuned X-galvanometer 5 1 to 3 months X-Axis galvanometer out of calibration Retuned X-galvanometer 5 1 to 3 months Low laser output power Retuned control circuit 5 1 to 3 months X-Axis galvanometer out of calibration Retuned X-galvanometer 5 3-6 months Galvanometer out of calibration Retuned galvanometer 5 3-6 months Galvanometer out of calibration Retuned galvanometer 5 3-6 months Galvanometer out of calibration Retuned galvanometer 5 6-12 months Galvanometer out of calibration Retuned galvanometer 5 6-12 months Galvanometer out of calibration Retuned galvanometer 5 6-12 months Galvanometer out of calibration Retuned galvanometer 5 Total 295 Table-1 Data of troubleshooting and repair analysis Table 1 shows total number of hours taken for repairs and replacement for the equipment in the month of October. The data is sorted to find which part contributes more in time taken for troubleshooting process

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Repair Action Sum of Total time taken Replace control board 10 Replace galvanometer and re-test 50 Replace Galvanometers and retest 20 Replaced faulty control circuit 30 Replaced laser 100 Replaced PSU 10 Retuned control circuit 5 Retuned control circuit and replaced galvanometer 15 Retuned galvanometer 30 Retuned X-galvanometer 25 (blank) 0 Grand Total 295 Table – 2 Table 2 Shows more filtered data about sum of total time taken by the repair action for the equipment. From the data we can see that major contributor are Replacement of Laser and Replacement of galvanometers. 4. LSS Project Definition Worksheet Project Definition Worksheet Project Title: Step Element Answer/Tool Identify the Business Gap What is the specific problem (project idea) affecting the success of your business? Failure rate in Laser inspection method / system Name the business metric associated with this problem (existing management performance indicator)? Troubleshooting Who are the internal and/or external customers most affected by this problem? Internal: Assembly technicians experiencing rework and troubleshooting delays. External: End users facing downtime and system unreliability. Is there competitive pressure creating a need to close this gap? No Is there a business strategy driving the need for a change? Yes Where is the problem occurring (geographic or process location)? Customer Location When was the problem first observed (specify month/year)? November

How Much? What is the extent or magnitude of the problem as measured by your business metric? 11 incidents in the month of october How do you know this is a problem? Report Data Compose a concise problem statement in sentence form. <When><what><where><howmuch><how do you know> When Time-of-Flight Laser Inspection Systems are in use, critical components like galvanometers and lasers frequently malfunction, causing inaccurate measurements or no power output, and necessitating costly repairs causing more than 50% of the issues. Document the Process What is the output product or service delivered to the customer related to the business problem? Return or Replacement Name the business process delivering the product or service. Think in terms of a process that can be mapped. Laser inspection system process Develop a High Level "As-Is" Process Map of the above business process. (Illustrate spatial/geographic flow if relevant to business gap.) This typically includes 5 to 7 major steps of a process. SIPOC, High Level Value Stream Map or Spaghetti Diagram Are there more than two business departments/functions/locations involved? If yes, the problem is likely too broad and a scoping session using scoping tools should be executed. Yes and the scoping tool is Pareto chart Collect & Translate the VOC What are the customer requirements? (Verbal and/or Numerical) Good quality product with no failure What are their specifications for each requirement? What are the performance gaps in satisfying the customer requirements? testing of product Is there a performance gap vs. your competition that needs to be closed? Which competitors? Which requirements? NO Which customer requirement(s) will be the focus of this improvement project? If more than 2 requirements are identified, the scope of the project may be too broad. No failure detection Define Metrics & Defects What is/are the defect(s)? NO Output, out of calibration Name the Primary Metric that measures the defect rate? (The Primary Metric) will be the yardstick for tracking success of the project. Time Name any Secondary Metric(s) that should improve as a result of completing the project. Laser Output Name the Consequential Metrics which measure potential negative consequences of successfully improving the Primary Metric. Identify which sources of data (reports, collection sheets, inspection points, etc.) are available to measure the metrics above. Incident report Is there sufficient historical data for all of the project metrics? If no data exists, then how do we know that there is a gap that needs to be closed? Yes How do the project metrics align with the business metrics? Decrease Failures Estab lish Preli mina ry Basel Create data collection plan if insufficient project metric data exists. Data Collection Plan

Estimate the Baseline performance level of this Primary Metric. Time for testing Estimate the Entitlement (best short term observed historical performance) and/or Benchmark of this Primary Metric. Develop Objective Statements Write a S.M.A.R.T. Objective Statement as follows: "Improve {primary metric} from {baseline level} to {target level (70% toward entitlement)} by {timeframe MM/YYYY}. Improve the failure rate of Time-of-Flight Laser Inspection Systems from 12% to 6% by 12/2024. 5. Gaps and Recommendations i) Five Original Gaps ➢ Root Causes Unknown: Analysis is based on failures, not the underlying reason why parts like galvanometers and lasers go out of spec in the first place. ➢ No Preventive Maintenance: There seems to be little focus on calibration or scheduled checks to catch problems before they leave the factory. ➢ Insufficient Quality Checks: Final testing may not be catching all defects. More inspection during assembly could reduce costs later. ➢ Joint Operations: Production and field service likely aren't sharing data/insights. Joint troubleshooting would speed up solutions. ➢ Reactive, not Proactive: There's no formal system to consistently use failure data to drive lasting improvements in the system's design or assembly. ii) Three Recommendations (With Priority/Timing): ➢ Root Cause Deep Dive (High Priority/Immediate): Focus on the top one or two failure types. Investigate potential causes in manufacturing, handling, or the component itself. This targets fixing things at the source. ➢ Galvanometer And Laser Calibration Protocol (Medium Priority/Short-Term): Implement a pre- installation calibration check, possibly coupled with post-install verification during commissioning. Could catch many failures upfront. Partner with your laser supplier: Are these defects on their end, or are they caused by damage during integration into your system? Enhance incoming inspection of laser components. Explore a more robust laser design option if the problem is found to be in that component itself. ➢ Enhanced Collaboration & Data Sharing (Medium Priority/Ongoing): Regular meetings between production and field service focusing on failure trends. Insights would guide both immediate fixes and longer-term design changes.

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Work Calculation From the table 2 we can assume that on average we have repair action on returns takes 5 hours and on replacement it takes 20 hours. Repair labor: Retuning at 5 hours, replacement at 20 hours Labor rate: $80/hour Total time taken for repairs = 295 Cost of these Repairs: = 295 X 80 = $23600 Majority of issues are with functions of Galvanometer and Laser. Replacement of Laser alone costs $8000 ( From the table No. of hours taken for replacement of Laser) Reference: Weeks 4 and 5 - Define Phase and Assignment #2 https://conestoga.desire2learn.com/d2l/le/content/1002147/viewContent/22052878/View

Assignment 2

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