Parts : TUB Family

Project : dent ,damage & Scratches

Process description
RM

INJECTION MOULDING

UNLOADING PARTS

STORAGE

DEFLASHING

CAP FIXING

STORAGE

INSPECTION

STORAGE

LOADING ON THE TROLLEY

MOVING

STOTAGE AT FG

LOADING ON THE TROLLEY - FOR DEPATCH

Part handing Condition
NA

PARTS - CATCH UP - RIB AREA

MANUAL UNLOADING

a. on floor
b. on trolley

Manual with knife

MANUAL FIXING

a. on floor
b. on trolley

VISUAL INSPECTION - ON FLOOR / TABLE

a. on floor
b. on trolley

TROLLEY -MANUAL

MANUAL MOVEMENT -FG

MANUAL STACKING /PART ON PART -

MANUAL LAODING ON THE TROLLEY

Possible causes
IMPROVEMENT PLAN ACTION NEED INVESTME
ACTION NO NEED INVESTMENT
 June July Aug
Defect des PPM Defect des PPM Defect des PPM
Mica mark 23393 short mould 21811 Start up 21945
Start up 19142 Mica mark 20130 Mica mark 20547
short mould 14409 Start up 17684 short mould 18658
Colour change 2203 Mould 2161 Black line 3427
Mould 2119 Colour change 1935 Mould 2570
Machine 1968 Black line 1523 Colour change 1911
Flow line 940 Machine 1090 Shrinkage 1023
Run out exess 720 Run out exess 989 Flow line 872

Shrinkage 487 Flow line 979 Contamination 622

Burn mark 471 Shrinkage 926 Run out exess 511
Black line 179 Void 737 Void 497
Warpage 178 Burn mark 386 Strain mark 479
Broken 136 Weld line 382 Burn mark 320
Void 131 Scratch 343 Scratch 251
Contamination 18 Broken 207 Weld line 204
Scratch 11 Strain mark 199 Machine 173
Strain mark 11 Warpage 158 Sink mark 102
Contamination 105 Broken 100
Gate blooming 62 Air leak 93
Sink mark 59 Warpage 91
Over melt 10 Over melt 75

Colour variation 4 SS 73

Colour variation 45

Gate blooming 45
Damage 31
Over cut 29
Based on the Analysis :
Root Cause Improvement Plan
on -line Short term Long term
1. Mica Mark
2. Short Mould
3.Start Up Rejection

Off line

Mica Mark
Printing problem
Scratches
Welding
 Sep
Defect des PPM
23393
Defect Pareto - June
Start up 24009 25000

PPM
19142
Mica mark 23182 20000
14409
short mould 20721 15000
10000
Shrinkage 1996
5000 2203 2119 1968 940 720 487 471
Flow line 1566 0
Mould 1271 Mica Start up short Colour Mould Machine Flow Run out Shrinkag Burn
mark mould change line exess e mark
Black line 1172
Colour change 1051
Defect Pareto - July
25000 21811
Contamination 974 20130
PPM

Run out exess 881 20000 17684

Void 866 15000

Burn mark 439 10000

Scratch 199 5000 2161 1935 1523 1090 989 979 926 737 386 382
Warpage 199 0
short Mica m ark Start up Mould Colour Black line Machine Run out Flow line Shrinkage Void Burn m ark Weld lin
Broken 169 m ould change exess

Weld line 165

Strain mark 163
Machine 161 Defect Pareto -Aug
Gate blooming 59 25000
21945
20547
SS 57 20000 18658
PPM

Sink mark 53
15000

Colour variation 32 10000

5000 3427 2570

1911 1023
872 622 511 497 479 320 251 204
0
Start Mica short Black Moul Colo Shrin Flow Cont Run Void Strai Burn Scrat Weld M
up mark moul line d ur kage line amin out n mark ch line i
d chan ation exess mark
ge

Defect Pareto - Sep

30000

25000 24009 23182

PPM

20721
20000

15000

10000

5000
1996 1566 1271 1172 1051 974 881 866 439 199
0
Start Mica short Shrink Flow Mould Black Colour Conta Run Void Burn Scratc
up mark mould age line line chang minati out mark h
e on exess
 fect Pareto - June

940 720 487 471 179 178 136 131 18 11 11

Flow Run out Shrinkag Burn Black Warpag Broken Void Contami Scratch Strain
ine exess e mark line e nation mark

Defect Pareto - July

979 926 737 386 382 343 207 199 158 105 62 59 10 4
ow line Shrinkage Void Burn m ark Weld line Scratch Broken Strain m ark Warpage Contam inati Gate Sink m ark Over m elt Colour
on bloom ing variation

efect Pareto -Aug

497 479 320 251 204 173 102 100 93 91 75 73 45 45 31 29

Void Strai Burn Scrat Weld Mach Sink Brok Air Warp Over SS Colo Gate Dama Over
n mark ch line ine mark en leak age melt ur bloo ge cut
s mark varia ming
tion

fect Pareto - Sep

974 881 866 439 199 199 169 165 163 161 59 57 53 32
onta Run Void Burn Scratc Warpa Broke Weld Strain Machi Gate SS Sink Colour
inati out mark h ge n line mark ne bloom mark variati
n exess ing on
June July Aug
Defect Qty Defect QTY Defect Qty
Mica Mark 19421 Scratch 4038 Mica Mark 3871
Short mould 5714 Mica Mark 2621 Scratch 2525
Scratch 3058 Welding 1461 Start up 1590
Welding 2397 Printing Problem 1419 Online Exess 1378
Weld line 2164 Start up 1239 Welding 1186
Start up 2054 Black Line 839 Strain mark 1016
Void 1234 Flow line 743 Contamination 794
Mismatch 1020 Warpage 708 Shrinkage 736
Mould 976 Short mould 668 Warpage 595
Burn mark 668 Damage 492 Short mould 478
Contamination 639 Over cut 452 Burn mark 401
Over cut 606 Shrinkage 426 Void 330
Printing Problem 500 Mismatch 411 Flow line 255
Damage 442 Colour Change 184 Damage 232
Run out exess 335 Colour Variation 181 Black Line 230
Black Line 318 Burn mark 180 Mould 220
Flow line 231 Strain mark 157 Weld line 168
Sink mark 229 Contamination 156 Over cut 156
Broken 183 Mould 110 Mismatch 145
Gate Blooming 145 Void 88 Colour Variation 113
Shrinkage 121 Silver streaks 82 Printing Problem 110
Strain mark 114 Run out exess 55 Knief Scratch 85
Warpage 75 Broken 48 Colour Change 82
Silver streaks 52 Sink mark 42 Silver streaks 41
Oil mark 25 Weld line 23 Broken 40
Machine 20 Knief Scratch 8
Colour Change 15
Knief Scratch 3
Sep
Defect Qty
Printing Problem 13185
Def
25000
Mica Mark 9728
Online Exess 6183 20000

No Rej
Scratch 6054
15000
Flow line 2363
Black Line 2201 10000
Warpage 1325
Shrinkage 1243 5000
Strain mark 1061
0
Welding 975 Mica Short Scratch Weldin Weld Start Void Mismat Mould Burn Co
Burn mark 746 Mark mould g line up ch mark mi
on
Mismatch 660
Start up 532
Contamination 337
Short mould 314
4500
De
Run out exess 290
4000
Pin mark 243
No of Rej

Over cut 222 3500

Weld line 182 3000

Damage 132 2500

Silver streaks 130 2000
Void 108 1500
Machine 67 1000
Gate Blooming 62 500
Oil mark 30
0
Broken 22 Scratch Mica Weldin Printing Start up Black Flow Warpag Short Damage
Mark g Proble Line line e mould
Knief Scratch 1 m

4500
De
4000
3500
No Rej

3000
2500
2000
1500
1000
500
0
Mica Scratch Start up Online Welding Strain Contami Shrinka Warpag Sh
Mark Exess mark nation ge e mo

De
14000
No of rej

12000
10000
 De
14000

No of rej
12000
10000
8000
6000
4000
2000
0
Printin Mica Online Scratch Flow Black Warpa Shrinka Strain Weldin
g Mark Exess line Line ge ge mark g
Proble
m
 Defect Pareto Off Line - June

Void Mismat Mould Burn Conta Over Printin Damag Run Black Flow Sink Broken Gate Shrink Strain Warpa Silver Oil Mac
ch mark minati cut g e out Line line mark Bloomi age mark ge streaks mark e
on Proble exess ng
m

Defect Pareto Off line - July

k Flow Warpag Short Damage Over Shrinka Mismat Colour Colour Burn Strain Contam Mould Void Silver Run out Broken Sink
line e mould cut ge ch Change Variatio mark mark ination streaks exess mark
n

Defect Pareto Off line -Aug

rain Contami Shrinka Warpag Short Burn Void Flow Damage Black Mould Weld Over Mismatc Colour Printing Knief Colour
ark nation ge e mould mark line Line line cut h Variatio Proble Scratch Change
n m

Defect Pareto off line - Sep

 Defect Pareto off line - Sep

k Warpa Shrinka Strain Weldin Burn Mismat Start Conta Short Run Pin Over Weld Damag Silver Void Machin Gate Oil
ge ge mark g mark ch up minatio mould out mark cut line e streaks e Bloomi mark
n exess ng
 Warpa Silver Oil Machin Colour Knief
ge streaks mark e Change Scratch

ver Run out Broken Sink Weld Knief

eaks exess mark line Scratch

ur Printing Knief Colour Silver Broken

tio Proble Scratch Change streaks
m
Void Machin Gate Oil Broken Knief
e Bloomi mark Scratch
ng
Quality circle for dent and scratches
Parts : TOP Family
Project : dent ,damage & Scratches

PARTS TOP FRAME CONDITION LID BOTTOM

RM RM

STOARGE AT RM STORE STOARGE AT RM STORE

INJECTION MOULDING INJECTION MOULDING

UNLOADING

STORAGE
Process description

DEFLASHING

CAP

STORAGE

INSPECTION

STORAGE

LOADING

MOVING

STOTAGE

LOADING
LID TOP MAX DRY HANDLE

RM OUTSOURCING RM

STOARGE AT RM STORE STOARGE AT RM STORE STOARGE AT RM STORE

INJECTION MOULDING INJECTION MOULDING

HINGE & BUSH GLASS

OUTSOURCING BOUGHT OUT

STOARGE AT RM STORE STOARGE AT RM STORE

Part handing Condition
NA

PARTS - CATCH UP - RIB AREA

MANUAL UNLOADING

a. on floor
b. on trolley

Manual with knife

MANUAL FIXING

a. on floor
b. on trolley

VISUAL INSPECTION - ON FLOOR / TABLE

a. on floor
b. on trolley

TROLLEY -MANUAL

MANUAL MOVEMENT -FG

MANUAL STACKING /PART ON PART -

MANUAL LAODING ON THE TROLLEY

Possible causes
IMPROVEMENT PLAN ACTION NEED INVESTME
ACTION NO NEED INVESTMENT