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Six Sigma Green Belt Project

1250-XX Covers
Reduction of Raw Material Cost by
Utilizing Regrind
Green Belt Candidate, Tempe
07/13/07

-DefineThe purpose of this project is to determine if the blending of 25% regrind into the
GE Ultem 1000 will significantly change the Key dimensional and visual
characteristics of the 1250-XX covers. We will focus on the 1250-05 for data
collection as this is our highest volume part for this Customer in this category.
If successful, this will eliminate the scrapping of the GE Ultem 1000 runners plus
reduce the amount of virgin material necessary to complete the orders.

-Process MapMaterial Purchasing

-MeasureMSA Instructions
Instructions:
-Using the Zeiss CMM program 1250-05 Six Sigma Post Only, run
sample parts in order. Samples are identified 1-10.
Setup (See pictures below):
Place 1.500 spacer in H2.(2x .750)
Place .750 spacer in H7. Position 1250-05 sample upside down on
spacer with gate at 45 degree angle to the bottom left. Snug down
with second .750 spacer.
Follow instructions contained in program for Base Alignment criteria.

Gate at 45 Degrees

-MeasureMeasurement System Analysis


Gage nam e:
Date of study:
Reported by:
Tolerance:
Misc:

Gage R&R (Nested) for 2.798 +/- .0


Components of Variation

By Part ID (Oper.)

Percent

100

%Contribution
%Study Var
%Tolerance

50

2.8015
2.8010
2.8005
2.8000

0
Gage R&R

Repeat

Reprod

Part ID
Oper.

Part-to-Part

1 2 3 4 5 6 7 8 9101 2 3 4 5 6 7 8 9101 2 3 4 5 6 7 8 910


Biljana
Kelley
Mike

R Chart by Oper.
Sample Range

0.00015

Biljana

Kelley

By Oper.
Mike

UCL=1.52E-04

0.00010

2.8015
2.8010

0.00005

R=4.67E-05

2.8005

0.00000

LCL=0

2.8000

Oper.

Xbar Chart by Oper.


2.802

Sample Mean

Zeiss
5-25-07
K. Miller
.010

Biljana

Kelley

Mike

UCL=2.801
Mean=2.801
LCL=2.801
2.801

2.800

Biljana

Kelley

Mike

Measurement System Analysis contd.


Less than 10% of the tolerance is taken up by measurement
error indicating that the Zeiss CMM program is an acceptable
way to accurately measure the Key characteristics.
Gage R&R
Source

VarComp

%Contribution
(of VarComp)

Total Gage R&R


Repeatability
Reproducibility
Part-To-Part
Total Variation

0.0000000
0.0000000
0.0000000
0.0000002
0.0000002

0.99
0.99
0.00
99.01
100.00

Source
(SV/Toler)

StdDev
%Tolerance
(SD)

Total Gage R&R


Repeatability
Reproducibility
Part-To-Part
Total Variation

0.0000483
0.0000483
0.0000000
0.0004832
0.0004856

Study Var
(5.15*SD)
0.0002488
0.0002488
0.0000000
0.0024885
0.0025009

%Study Var
(%SV)

9.95
9.95
0.00
99.50
100.00

2.49
2.49
0.00
24.88
25.01

-MeasureKey Dimension Capability using 100%


Virgin Material
Process Capability Sixpack for 2.798(100%V)
Xbar and R Chart

2.8017

Capability Histogram
UCL=2.802

Mean

2.8016
Mean=2.802

2.8015
2.8014

LCL=2.801
2.8014

Subgr 0

10

15

Range

0.00024

2.8016

Normal Prob Plot


UCL=2.26E-04

0.00016
0.00008

R=6.92E-05

0.00000

LCL=0
2.8014

Last 15 Subgroups

2.80165

Values

2.8015

Overall
StDev: 0.0000646
Pp:
25.79
Ppk:
7.61

2.80145
2.80135
0

10

Subgroup Number

15

2.8016

Capability Plot

Within
StDev: 0.0000614
Cp:
27.17
Cpk:
8.01

2.80155

2.8015

Process Tolerance
Within
III

Overall
I

2.793

III

Specifications

2.803

-MeasureKey Dimension Capability using 100%


Virgin Material
Process Capability Sixpack for .140(100%V)
Xbar and R Chart
0.1380

Mean

Capability Histogram

UCL=0.1380

0.1378
Mean=0.1377

0.1376
0.1374

LCL=0.1373
0.1372

Subgr 0

10

15

Range

0.0006

0.1376

Normal Prob Plot


UCL=5.92E-04

0.0004
0.0002

R=1.81E-04

0.0000

LCL=0
0.13750

Last 15 Subgroups
0.1378

Overall
StDev: 0.0001786
Pp:
3.73
Ppk:
3.10

0.1376
0.1374
0

10

Subgroup Number

15

0.13775

0.13800

Capability Plot

Within
StDev: 0.0001606
Cp:
4.15
Cpk:
3.44

0.1380

Values

0.1380

Process Tolerance
Within
I

I
I

0.136

Overall
I

Specifications

0.140

-MeasureKey Dimension Capability using 100%


Virgin Material
Process Capability Sixpack for Parallel(100
Xbar and R Chart

0.0074

Capability Histogram
UCL=0.007337

Mean

0.0072
Mean=0.007065

0.0070
0.0068

LCL=0.006793
0.0066

Subgr 0

10

15

Normal Prob Plot

0.00030
0.00015

R=1.45E-04

0.00000

LCL=0
0.00680

Last 15 Subgroups
0.0071

Overall
StDev: 0.0001202
Pp:
13.87
Ppk:
8.14

0.0069
0.0067
0

10

Subgroup Number

15

0.00705

0.00730

Capability Plot

Within
StDev: 0.0001281
Cp:
13.01
Cpk:
7.63

0.0073

Values

0.0074

UCL=4.72E-04

0.00045

Range

0.0070

Process Tolerance
Within
II I

Overall

II I

0.00

Specifications

0.01

-MeasureKey Dimension Capability using 25%


Regrind
Process Capability Sixpack for 2.798(25%R)
Xbar and R Chart

2.8015

Capability Histogram
UCL=2.801

Mean

2.8014
Mean=2.801

2.8013
2.8012

LCL=2.801

1
Subgr 0

10

2.80100

15

2.80125

2.80150

Normal Prob Plot

0.0003

Range

UCL=2.62E-04
0.0002
0.0001

R=8.01E-05

0.0000

LCL=0
2.8011

Last 15 Subgroups
Values

2.8013

Overall
StDev: 0.0000894
Pp:
18.65
Ppk:
6.26

2.8012
2.8011
0

10

Subgroup Number

15

2.8015

Capability Plot

Within
StDev: 0.0000710
Cp:
23.47
Cpk:
7.88

2.8014

2.8013

Process Tolerance
Within
III

Overall
I

2.793

III

Specifications

2.803

-MeasureKey Dimension Capability using 25%


Regrind
Process Capability Sixpack for .140(25%R)
Xbar and R Chart

Capability Histogram

Mean

0.13775

UCL=0.1377

0.13750
Mean=0.1374
0.13725
0.13700

LCL=0.1370
0.13700

Subgr 0

10

15

Normal Prob Plot

0.0004
0.0002

R=1.95E-04

0.0000

LCL=0
0.1370

Last 15 Subgroups
0.1374

Overall
StDev: 0.0001758
Pp:
3.79
Ppk:
2.60

0.1372
0.1370
0

10

Subgroup Number

15

0.1374

0.1378

Capability Plot

Within
StDev: 0.0001728
Cp:
3.86
Cpk:
2.64

0.1376

Values

0.13750

UCL=6.37E-04

0.0006

Range

0.13725

Process Tolerance
Within
I
I
I

0.136

Overall

Specifications

0.140

-MeasureKey Dimension Capability using 25%


Regrind
Process Capability Sixpack for Parallel(25%
Xbar and R Chart

Capability Histogram

Mean

0.00735

UCL=0.007317

0.00710
Mean=0.006979
0.00685
LCL=0.006640

0.00660

0.0066

Subgr 0

10

15

0.0006

Range

0.0071

Normal Prob Plot


UCL=5.88E-04

0.0004
0.0002

R=1.80E-04

0.0000

LCL=0
0.0066

Last 15 Subgroups
0.00730

Overall
StDev: 0.0001662
Pp:
10.03
Ppk:
6.06

0.00705
0.00680
0

10

Subgroup Number

0.0071

15

0.0076

Capability Plot

Within
StDev: 0.0001597
Cp:
10.44
Cpk:
6.31

0.00755

Values

0.0076

Process Tolerance
Within
I II

Overall

III

0.00

Specifications

0.01

-MeasureKey Dimension Capability using 100%


Regrind
Process Capability Sixpack for 2.798(100%R)
Xbar and R Chart

2.8018

Capability Histogram

Mean

UCL=2.802
2.8016
Mean=2.801
2.8014
LCL=2.801
2.8012

2.80120

Subgr 0

10

15

2.80145

2.80170

Normal Prob Plot


UCL=3.59E-04

Range

0.0003
0.0002
0.0001

R=1.10E-04

0.0000

LCL=0
2.80120

Last 15 Subgroups

Values

2.8018
2.8016
2.8014
2.8012
0

10

Subgroup Number

15

2.80145

2.80170

Capability Plot

Within
StDev: 0.0000975
Cp:
17.10
Cpk:
5.19

Process Tolerance
Within

Overall
StDev: 0.0001271
Pp:
13.12
Ppk:
3.98

Specifications

III

Overall
I

2.793

III
I

2.803

-MeasureKey Dimension Capability using 100%


Regrind
Process Capability Sixpack for .140(100%R)
Xbar and R Chart

Capability Histogram
UCL=0.1378

Mean

0.1378
0.1376

Mean=0.1375
0.1374
LCL=0.1372

0.1372

0.13720

Subgr 0

10

15

0.13745

0.13770

Normal Prob Plot

0.0006

Range

UCL=5.24E-04
0.0004
0.0002

R=1.60E-04

0.0000

LCL=0
0.13720

Last 15 Subgroups
Values

0.1378
0.1376
0.1374
0.1372
0

10

Subgroup Number

15

0.13745

0.13770

Capability Plot

Within
StDev: 0.0001422
Cp:
4.69
Cpk:
3.55

Process Tolerance
Within

Overall
StDev: 0.0001915
Pp:
3.48
Ppk:
2.64

Specifications

I
I

0.136

Overall
I

0.140

-MeasureKey Dimension Capability using 100%


Regrind
Process Capability Sixpack for Parallel(100
Xbar and R Chart

Mean

0.0072

Capability Histogram
UCL=0.007158

0.0070

Mean=0.006941

0.0068
LCL=0.006723

0.0066

0.00660

Subgr 0

10

15

0.00685

0.00710

Normal Prob Plot

0.00045

Range

UCL=3.78E-04
0.00030
0.00015

R=1.16E-04

0.00000

LCL=0
0.00660

Last 15 Subgroups

Values

0.0072
0.0070
0.0068
0.0066
0

10

Subgroup Number

15

0.00685

0.00710

Capability Plot

Within
StDev: 0.0001026
Cp:
16.24
Cpk:
9.94

Process Tolerance
Within

Overall
StDev: 0.0001186
Pp:
14.05
Ppk:
8.60

Specifications

III

Overall

II I

0.00

0.01

-AnalyzeA t-Test is being used to show that there is no significant difference


in the means between the 100% Virgin material and the Virgin
material with 25% Regrind. With the P-value being greater than
Alpha (.05), we fail to reject the Null Hypothesis (Ho) on all 3 Key
Characteristics.

-AnalyzeContd.

-AnalyzeContd.
Samples were run with 100% Regrind to see what effect it had on the
Key Characteristics.
t-Tests were used to show if a significant
difference in the means had been caused by the change. With P-values
remaining greater than Alpha (.05), we fail to reject the Null
Hypothesis (Ho) on all 3 characteristics proving there is no significant
difference in dimensional readings when 100% Regrind is used.

-AnalyzeContd.

-ImproveThe Improvement phase will implement the usage of 25% Regrind


added to the virgin material during normal production runs. The
Work Order template will be updated in the Shared Directory to
accurately reflect the percentage of regrind allowed. Correct
usage of material will be verified during the QA Sign-In and
initialed. The Bill of Materials will also be amended.

-ControlThe Customer defined Key Characteristics will be monitored after


the introduction of regrind during the molding operation using a
variety of tools. Sign-In and In-Process dimensional inspection
criteria are controlled and communicated via the Mold Data
Book. The QA Sign-In at the start of the run will include the
Customers current A-079 inspection form available from their
Customer Website. In-Process data will be entered into real-time
SPC Charts in the Quality Control Lab and will be monitored by
Quality Inspectors. Any unusual variation in the SPC Charts will
be investigated. Out of specification product will be quarantined
and properly labeled with an Non Conforming Material Report
per the ISO standard and dispositioned accordingly.

-ControlCopy of Mold Data Book PageSign-In Criteria

Copy of Mold Data Book PageIn-process


Dimensional Inspection criteria.

-ControlSample Customer A-079 Inspection Form

-ControlCopy of Blank NCMR

Sample SPC Chart

-Cost Savings-

-Cost SavingsExtrapolated to include all the 1250-XX Covers that do not specify
100% Virgin Only including -02, -05, -08, -10, -11, -12:

-ConclusionAfter measuring samples run with 25% Regrind/75% Virgin and


samples run with 100% Regrind, it has been concluded that
there were no significant differences or changes in the
Customers Key Dimensions. Cpk levels ranged between 2.64
and 9.94 indicating all values are well above the 2.00 Cpk of a
stable 6-sigma process. Taking into account normal process
variation and the likeliness that the process may drift, it can be
assumed that the values will remain within the Customers
specifications.
Tensile strength testing will need to be done by the Customer to
verify overall strength and integrity has not been compromised
due to this change.
With an annual savings of $5,687.34 for the -05 configuration,
the potential cost savings if applied to all of the 1250-XX part
numbers would be $13,655.25 annually.