DMAIC

FLASH V1

DMAIC Project

Quality & Continuous Improvement Management

Phase: EFINE

Define baseline, objectives and work team

Business case

V1 With more than 200 defect on 26 molds validated (Jan-Feb 2023)

GOALS

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Reduce flash on molds by 30%

Objectives

KR

Without flashes on plastic part of validation 1

Key Results

Team Work

Roles and responsibilities

Rafael Delgado

Andres Lopez

Q &C.I. ManagerProject development / Black Belt

Programming LeaderMachining strategies

Carlos Estrada

Patricia Cruz

Shop ManagerDefinition of variables / Mold Making Expert

Quality System Sr CoordinatorAnalysis of variables / Documentation of improvements

Joe Jeffrey

Francisco Olan

Manufacturing ManagerVariable definition/ Machine Expert

Continuous Improvement EngineerAnalysis of variables/design of experiments/analysis of results

Ruben Rodriguez

Christian Mora

Schedule Manager Time planning / Machines

Maitenance Coordinator Machine analysis/TPM

Miguel Garrido

Carlos Ramirez

Job Logistic CoordinatorV0 results in molds / Root cause analysis

MM-Spotting Supervisor Definition of problem/spotting times

Base line

Major flaws in V1

Data obtained from 26 molds with V1 during Jan-Feb 2023Major defect present:

• Flash (296 issues)

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Goal 1

Potential process variables

potential variables to analyze

• Type of tool used (flat/ball/etc)
• Tool Life (Wear)
• Machining strategy (lack of standardization in programmers)
• Enviroment temperature (3° - 30°)
• Rommer arm (variation between measurements)
• Holder condition (tool state)
• Screw temperature (Index of thermal expansion)
• TPM (Machine in optimal conditions)
• Seal type (flatness, angle, slope and transition actors)

Goal 1

Define process variables

Variables to analyze

Review machining strategies:

• A) Diferent strategies of programs
• B) Program diferents surfaces
• C) Create core/cavity test block (Promac VT/Promac 001/Promac 004/ DMG 125U)
• D) Analyze spotting on test block
• E) Run MSA for rommer arm
• F)Validate TMP before and after use to machine
• G) Define good machining practices (use of RTCP more frequently)

Variables and strategies

Test blocks 1 & 2 Set A

Results

Test blocks 1 & 2 Set A

Axis PARALLEL

Chord error

reductions

45°

0.00004”

5 Axis

Results

Learned lessons (Machining strategies)

Test Block

Shift A-B

Learned lessons (Mold Making)

Test Block

Set 1

Seal test in test block °2

Machined with a very good finish on stamp and figure, vibrated finish on boxes (machine problem), the stamp is achieved by retouching verticals and radii.

Advance in strategies for machining

7 hours

Machining time

57%

Variation between zones

1 hour

adjustment time

Spotting Test

Key Points

• Seal zones A-B-C make contact at the same time
• Only verticals and angles are touched
• Test shows clip displacement, should be corrected for next test
• Machine finish good for polishing
• Steps can be seen in the area of the plastic piece (near the wall)

Next Steps

Step 1

step 4

step 3

STEP 2

step 1

Perform spotting test and collect new data

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Make corrections in programming and machining strategy

Carry out planning and test machining

Request advice from Gustavo Barrera for design modification

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¡Thank You!