【正文】 Jan 99Mar 99May 99Jul 99Sep99Nov 99Jan 00Mar 00May 00M o n t hCost ($)6 1 E S c r a p / R e w o r kC o s t s ( $ ) 9 . Secondary Metric In order to show that the improvements in the reduction of scrap/rework costs is not fluctuating with changes in total production, the Secondary Metric shows the cost of scrap/rework due to 61E errors as a percentage of the total sales value for each month. The graph below relates to the quantity of stators faulted against the total number tested as plete wound stators during the same period due to 61E faults. Down is Good % 6 1 E S c r a p o f S a l e s V a l u e00 . 0 20 . 0 40 . 0 60 . 0 80 . 10 . 1 2Jan 99Mar 99May 99Jul 99Sep99Nov 99Jan 00Mar 00May 00M o n t h%% 6 1 E S c r a p o fS a l e s V a l u eQ t y o f 6 1 E F a u l t s A g a i n s t Q t y o f S t a t o r s T e s t e d05001000150020xx2500Jan 99Mar 99May 99Jul99Sep 99Nov 99Jan 00Mar 00May 00M o n t hQty Tested051015202530Qty RejectedS t a t o r s T e s t e dQ t y R e j e c t e d 10 Similarly as a percentage of the total number of stators produced, the historical data collected shows that without any actions or controls in place, the quantity of faults tends to follow any fluctuations in production. . Process Capability The historical data shown above indicates that over the twelve month period from March 1999 to March 20xx, the average defect rate per month for 61E faults equates to 4000 parts per million. With the FMEA Action Plan in place, the team expect to see the average defect rate per month reduce to less than 20xx parts per million during the eighteen month follow up period. . Other business benefits Improved throughput efficiency both in Electrical Design and Winding Department due to the reduction in rework involved. Contribute to achieving better due date performance as part of IBC Guiseley’s 5x5 objectives. Reduction in waste and costs incurred. Down is Good % F a u l t s o f S t a t o r s T e s t e d ( Q t y )00 . 511 . 52Mar 99May 99Jul99Sep 99Nov 99Jan 00Mar 00May 00M o n t h% % F a u l t s 11 3. TEAM DEFINITION AND SELECTION . Definition ? Champion Eriks Zvaigzne ? Black belt Bob Eddison ? Green belt Stephen Dale ? Team Eric Nelson (Elec Design process expert) Frank Jones (Elec Design process expert) Karen Claughton (Winding supervisor – hand/veser) Andy Bodkin (Winding supervisor – machine) David Bullock (Technical expert, accounts) . Selection The team was selected with the aim of utilising a range of skills, experience and expertise from the process of electrical design through to the production of plete wound stators in the Winding department. This included David’s knowledge of the puter programs which extract electrical design information in order to produce winding information on the winding orders. Initially the team were given a brief introduction to the project and its objectives, before being provided with an overview of some of the tools that could be used in order to highlight problem areas. It was stressed that team working would be vital towards the success of the project, and future meetings would involve some or all of the team members depending on the expertise required for each tool being used. The following pages show the results of the work carried out by the team. 12 4. PROCESS MAPPING AND CAUSE amp。 P A RA L L E L SF O R DE S I G NP RA CT I CA L No . O FT URN S amp。par a l l e l sC orr e c t no ofl e a ds (6,9 or 1 2 )Fi nde ffec ti v eno tu r ns amp。pa r a lle lsC or r e c t no ofle a dsFinde ffe c tiv eno tur ns amp。 P W S M o to r sC o m p u t e r c a l c a c c e p t s w r o n g p a ra l l e l sN o t a w a re s p e c i a l ru l e s e x i s t W d g d i a g re f 39。s N o c o m m o n f o r m a t o r i d t o d i a g re f 39。 Pa ra l l e l s Vo l t a g e Su p p l y 8 102 56D e s i g n C a l cu l a t i o n (w d g s p e c) 7 5 103 74N u m b e r o f St a t o r Sl o t s 6 6 104 72C o n n e ct i o n s 6 6 9 1 105 123Me t h o d o f St a rt b o t h Sp e e d s 4 8 2 106 86Po l e C o m b i n a t i o n s 4 7 107 63C i rcu l a t i n g C u rre n t R u l e s 8 2 9 108 11300C h e ck N u m b e r o f L e a d s F u l l L o a d C u rre n t s 7 109 42Me t h o d o f St a rt b o t h Sp e e d s 7 110 42C o n n e ct i o n s 6 111 36C i rcu l a t i n g C u rre n t R u l e s 4 112 2400000000000000C h a r a c t e r i s t i cS e l e c t i o n M a t r i xI n i ti a l Stu d y D a te : 2 2 . 0 3 . 0 0 Pa g e : 2 of 4C u r r e n t R e v i s i o n D a te : 2 6 . 0 5 . 0 0 Pr o d u c t: W I N D I N G D I A G R A M R EF ER EN C ESG r e e n b e l t: ST EPH EN D A L E Pr o c e s s : Se l e c t T a p p e d W d g C o n n e c ti o n sR a t i n g o f I m p o rt a n ce t o C u s t o m e r = = 4 7 7 6KPOVNumber of WindingsSuitable no turns amp。 Pa ra l l e l s Vo l t a g e Su p p l y 7 306 49D e s i g n C a l cu l a t i o n (w d g s p e c) 5 6 5 5 307 143C o i l Pi t ch 4 6 8 5 3 308 154Ba s i c W i n d i n g D i a g ra m 2 1 7 309 62N u m b e r o f St a t