Team One Phase II Short Form 1

Team One Phase II Short FormTeam Members

Jeremiah Jones*David KarlKris PiersonKyle RenfroBrian OwensMichael Hipp**Dr. John W. Sinn***

*Assistant Team Leader

**Team Leader***Team Mentor

Team One Phase II Short Form 2

Project Plan• To evaluate current resources available to the die cast

industry for process data acquisition and the use of this data in a quality system.

Team One Phase II Short Form 3

Project Summaryby Michael Hipp• Plant Quality System

– Quality system is a robust and thorough set of documented procedures – QS-9000 certified

• Current Status of Project– Reviewing data acquisition and analysis tools– Continuous improvement is the key

• Progress within Team One– Project focus improving– Continuous improvement is the key

Team One Phase II Short Form 4

Toolkit Applicationsby Kyle Renfro

• Toolkit 24 Applications– Normal Curve– Histogram– Standard Deviation Calculation

• Toolkit 25 Applications– P-Chart– X-bar & R chart– Data Collection, Recording and Analysis of Data

Team One Phase II Short Form 5

Toolkit Applicationsby Brian Owens

• Scrap Reduction by use of Inspection– Continuous Inspection– Automated Data Collection Machine– Catching Scrap at the Source

• Value of Charting– Converts Raw Data into Useful Data– Shows Trends that Can Help Process Improvement– Gives History of Defect/Cause Relationships

Team One Phase II Short Form 6

Information Reviewsby Kris Pierson

• Statistical Process Control (SPC)

– Decrease Scrap, Rework, and Inspection– Decrease Operating Costs– Increased Productivity– Increase Quality and Process Control

• The Improvement of Measuring Surface Quality

– Evaluation of Surface Shape– Detects the Slightest Flaws that Impair Appearances– Improves Quality Assurance and Data Acquisition– Continuous Improvement of Quality Control Equipment

Team One Phase II Short Form 7

Information Reviewsby Kris Pierson

• Die Casting Defects

– Identifying and Eliminating their Cause– Problem Solving and Record Keeping Systems– Variable Statistics in the Production Process– Statistics and Process Capability

• Development and Evaluation of Sensor Systems

– Document Data about Die-Casting Operation– Die-Cast Process Complex and Sensitive– All Cast Defects are Preventable– Test Engineering Theories about Die-Cast Operation

Team One Phase II Short Form 8

Information Reviewsby Kris Pierson

• Attribute Charting

– Method Used to Determine Process Problems– Statistical Process Control (SPC)– Data counts the Number of Times a Failure Occurs– Control Charts Monitor Process and Location

• Integrating HACCP and TQM

– Electronic Vision Monitoring System– Monitors and Documents Deviations– Defect Attributed to Specific Unit Operation– Total Quality Management (TQM)

Team One Phase II Short Form 9

Information Review Abstractby David Karl

• Die Cast Machine– Uses Molten Aluminum to Make Parts– Quality Control in Die Cast Variables

• Advantages of Die Casting– Pieces per Hour– Lack of Extra Operations

Team One Phase II Short Form 10

Information Review Abstractby David Karl

• Quality Control on Die Cast Machines– Downtime Logging– Scrap Logging– Continuous Data Collection– Downloading/Uploading Machine Setups– Alarm/Report Editor– Closed Loop Controls

Team One Phase II Short Form 11

Information Review Abstractby David Karl

• SPC Charts– X-Bar and R Charts– Scatter Diagrams– HiLo Range Charts

• Reports– Shot Summary Reports– Data Log Reports– Hard Copy Reports

Team One Phase II Short Form 12

Evaluations of Team Henry and Team Dana by Brian Owens

Team Performance Analysis

0

5

10

15

20

25

30

35

Tool D Tool B Tool C Tool 24 Tool 25 Tool 26

Tool Kit

Sco

re

Dana

Henry

Acme

Team One Phase II Short Form 13

Team One Self-Evaluationsby Jeremiah Jones

• Team Evolution– Evaluation Sheets– Changes Made

• Team Meetings– Chat Room– Personal Meetings– Forming Goals

Team One Phase II Short Form 14

Team One Self-Evaluationsby Jeremiah Jones

• Editing Our Submission• Timeliness

– How It Has Hurt The Team– Actions That Have Been Taken– Where We Stand Now

Team One Phase II Short Form 15

TEAM ONE EVALUATIONSThree evaluation categories worth 5 points each

Evaluations for the weeks of: 3/22/00 and 3/29/00Group Average: 13.8 (out of 15) Group %: 92%

Evaluation completed by:

Member & Category

Brian Kyle Kris Dave Jeremiah Michael

Brian Owens AverageParticipation 4 4 3 3 5 4Timeliness 4 4

Content 4 3 4 3 5 412

Kyle RenfroParticipation 5 5 4 4 5 5Timeliness 5 5

Content 4 4 4 4 5 414

Kris PiersonParticipation 4 4 4 3 2 3Timeliness 5 5

Content 5 5 4 4 5 513

Dave KarlParticipation 5 5 5 5 5 5Timeliness 5 5

Content 5 5 5 5 5 515

Jeremiah JonesParticipation 5 5 5 4 5 5Timeliness 5 5

Content 5 5 4 4 5 514

Michael HippParticipation 5 5 5 5 5 5Timeliness 5 5

Content 5 5 5 5 5 5Total Points: 15

Team One Phase II Short Form 16

Weekly Task List

MFG 326 Team One Group Weekly Task List

Deliverable Due Date Summary Info. Review Info. Review Info. ReviewTeam Henry Evaluation

Team Dana Evaluation

TTL B 1/26 Brian Kyle Jeremiah Dave Michael KrisTTL D 2/2 Kris Brian Kyle Jeremiah Dave MichaelTTL C 2/9 Michael Kris Brian Kyle Jeremiah Dave

Phase One 2/23 (See separate description for phase work)

TTL 24 3/1 Dave Michael Kris Brian Kyle JeremiahTTL 25 3/15 Jeremiah Dave Michael Kris Brian KyleTTL 26 3/22 Kyle Jeremiah Dave Michael Kris Brian

Phase Two 4/5 (See separate description for phase work)

TTL 27 4/12 Brian Kyle Jeremiah Dave Michael KrisTTL 28 4/19 Kris Brian Kyle Jeremiah Dave Michael

Phase Three 5/3 (See separate description for phase work)

Note: Applications are evenly divided among team members for each toolkit.

MFG 326 Team One Group Phase Report Task List

Deliverable Due Date SummaryTTL B

ApplicationsTTL D

ApplicationsTTL C

ApplicationsTeam

EvaluationsInformation

ReviewsPhase I 2/23 Michael Kris Dave Jeremiah Kyle BrianPhase II 4/5 Kris Dave Jeremiah Kyle Brian MichaelPhase III 5/3 Dave Jeremiah Kyle Brian Michael Kris

Team One Phase II Short Form 17

Thank you for your time!

Please feel free to ask questions.