热电偶CI000

Page1QuicklychangethermocouplePage2Issue:Theme/ReasonForSelection1.Thermocoupleistoolongthenitneedbebentandenlaced.2.Oncethermocoupleisdamaged,alsoneedtoexpendmanytimetochangeit.Thethermocouple:connecterleadthermocouplefunction:measureandmonitortemperatureofmolddiePage3SPC:35-65gTheD/BbondingforceSPC:35-65gTheD/BbondingforceUnderstandingCurrentSituationCI-Step-2Ittakemanytimeforchangingonebadthermocouple.510152025303540Time(minute)L1335L3935L3040L4306L4947L3203L3197L4624L0739L2636TechAvg=20.81LCL=7.65UCL=33.97IndividualMeasurementofTime(minute)051015MovingRangeofTime(minute)L1335L3935L3040L4306L4947L3203L3197L4624L0739L2636TechAvg=4.95LCL=0.00UCL=16.17MovingRangeofTime(minute)ControlChartPage4CI-Step-2UnderstandingCurrentSituationwhenathermocoupleisbadandneedchange,sometechniciandon’ttakeoutbadthermocouple,onlyaddaanewthermocoupletoreplacebad,effectitsappearanceand5S.Page5SPC:35-65gTheD/BbondingforceSPC:35-65gTheD/BbondingforceCI-Step-3GoalSetting&PlanGoal:ReducethetimeforchangingabadthermocoupleFromavg.20mintoavg.5minImprovementmold5SDuedate:ww28’2007Page6CI-Step-4De-runnerdegaterunnerPickupL/FonloaderMoldprocessPutL/FintomolddieOutlineofEquipment&ProcessTemperaturecheck=SizetemperatureHeatoffHeatonFlowoftemperaturecontrollingsystemMolddietemperature180℃YNHeatcontrollerMolding&CureTPFEPage7CI-Step-5ClarificationofPhenomenon/ProblemCheckandconformthermocoupleChangeortakedownbadthermocoupleFindtemperatureabnormalDuringPMwork(hydraulic.PM&MolddiePM)VerifythethermocouplesDisentanglecircuitTakedownbadthermocoupleSetnewthermocoupleEnlacedcircuitTrackingChangeprocessWastemoretimeandthethermocouplescouldbedamagedeasy.Page8TimeanalysisEnlacedcircuit54%Disentanglecircuit24%Changebadparts22%CI-Step-6Timeanalysis(Level1):RootCauseAnalysisDisentanglecircuitchangebadpartsEnlacedcircuitL0474325L1335348L47605515L39355718L179510416L30408107L1653226L4306429L2048366L49473210L40365510L32036410L4386429L31974412L47755412L4624447L09428715L07397515L46295712L26368715L19795515Average5511Page9CI-Step-7CountermeasuresABCOriginalTT0σBdTT0TσAdTTT0σCdTπCA()T0πBC()T0πAB()TABCimprovementTT0σBdTT0TσAdTTT0σCdTπCA()T0πBC()T0πAB()TControlsystemControlsystemconnecterAddedconnecterTheorysupport:MeanConductorLaw:EABC()T0T,πAB()TπBC()T0πCA()T0+=+=EAB()T0T,Accordingtomeanconductorlaw,accuracyofthermocouplehavetodowithtemperatureofthermocoupleheadonly.Page10CI-Step-7Action:Modifythermocouplestructurefromholistictosubsection,reducelengthofcircuitfrom1500mmto1000mm.CountermeasuresAftermodify:Beforemodify:thermocouple1400-1500mm800mmconnecter200mmthermocouplePage11CI-Step-7CountermeasuresOverallnewthermocouplearecalibratedandpassedbyQA.DepartmentInstrument_numberInstrument_descriptionBrandModelStatusLast_due_dateCalibration_dateCycle_timeExpiry_dateResponsible_personnelCalibration_referenceRemarkB/E-1M220215301ThermocoupleChongqingChangyiKActive2007-4-2462007-10-23ZhangXuezheng;XuLinCal.ProcedureseetherecordB/E-1M220215401ThermocoupleChongqingChangyiKActive2007-4-2462007-10-23ZhangXuezheng;XuLinCal.ProcedureseetherecordPage12CI-Step-7Tracking:174175176177178179180181182183184185186Column2NewOriginalColumn1EachPairStudent'st0.05NewOriginalLevel178176Minimum178178.110%17817925%180179.5Median18118075%181.418190%182181MaximumQuantilesRsquareAdjRsquareRootMeanSquareErrorMeanofResponseObservations(orSumWgts)0.000138-0.034341.282116179.451631SummaryofFitOriginal-NewAssumingequalvariancesDifferenceStdErrDifUpperCLDifLowerCLDifConfidence-0.029170.460790.91325-0.971590.95tRatioDFProb|t|ProbtProbt-0.0633290.95000.52500.4750-1.5-1.0-0.5.0.51.01.5tTestColumn1ErrorC.TotalSource12930DF0.00658647.67083347.677419SumofSquares0.006591.64382MeanSquare0.0040FRatio0.9500ProbFAnalysisofVarianceNewOriginalLevel1516Number179.467179.438Mean0.331040.32053StdError178.79178.78Lower95%180.14180.09Upper95%StdErrorusesapooledestimateoferrorvarianceMeansforOnewayAnovaOnewayAnovaNewOriginalLevel1516Number179.467179.438Mean1.407461.15289StdDev0.363410.28822StdErrMean178.69178.82Lower95%180.25180.05Upper95%MeansandStdDeviations2.04523t0.05AlphaNewOriginal-0.95750-0.91325-0.91325-0.92710Abs(Dif)-LSDNewOriginalPositivevaluesshowpairsofmeansthataresignificantlydifferent.ComparisonsforeachpairusingStudent'stMeansComparisonsOnewayAnalysisofColumn2ByColumn1UpperlimitLowerlimitCollectMP10allchase’stemperatureon23and24’Apr.CountermeasuresPage13CI-Step-7CountermeasuresBeforeVsAfterDisentanglecircuitTakebadthermocoupleSetnewthermocoupleEnlacedcircuitLoosemiddleconnecterTakebadthermocoupleheadSetnewthermocoupleheadTrackingTrackingAveragesavetime15minuteperthermocoupletodisentangleandenlacedcircuit.Page14CI-Step-8EffectivenessVerification051015202530minuteL0474L4760L1795L1653L2048L4036L4386L4775L0942L4629L1979L3935L1335L1979L0942ChangeTime02468Time(minute)L4760L3935L3029L1335L1975L1979L0739L0942TechAvg=4.00LCL=0.96UCL=7.04IndividualMeasurementofTime(minute)ControlChartNewOriginalTrackMP10status,decreasechangetimefromaverage20mimutesto5minutes,improvemoldmachine5s,achieveteam’sgoal.Page15Financ