SHD COVER SCRAP PROBLEMS

September 12, 2002 Meeting

Present: John Howze, James Lincoln, Darrin McCain, Loyd Aga, Terry Pille, Jerry Brown, Bill Evans

Cc: Scott Daniel


Identify the Problem: Scrap for SHD Covers in August was $X,XXXX.

A) BLISTERS - 954

B) SMALL BISCUITS - 884


Exploit (Identify causes and cures)

Possible Causes: A) BLISTERS

Issues with blisters

(1) Trapped Air

(2) No Water

(3) Metal Temperature too high


Possible Cures: BLISTERS - Issues 1-3

Issue (1) - Possible Causes

Radius leading into center section of parts between ribs is larger on Cavity #6 than Cavity #5

Increase vent widths in two locations

Increase part thickness were blisters occur

Not cleaning out vents & improper spray pattern by operator

Shot parameters not set correctly

Large step in gate where shot block insert meets cavity inserts (need to blend)


Issue (1) - Possible Cures and Actions Required:

Jerry Brown and Bill Evans write tool ticket to:


Issue (2) - Possible Causes

Water not hooked up at Set-Up

Water turned off during production

Lack of water supply


Issue (2) - Possible Cures and Actions Required:

D/C Foreman to ensure the water is properly hooked up, turned on and sufficiently flowing.


Issue (3) - Metal Temperature too high

Issue (3) - Possible Cures and Actions Required:

James Lincoln to get EP to check furnace to ensure the proper settings

James Lincoln & D/C Foreman to instruct furnace tenders on proper metal temperature

Jerry Brown modify set-up sheets to verify metal temp- (temp min/max /do not run below)







Identify the Possible Causes : B) SMALL BISCUITS

Possible Causes: SMALL BISCUITS

Issues with B) SMALL BISCUITS:

Issue (1) - Operator Not Pouring Enough Metal in Chamber

Issue (2) - Die Spitting


Issue (1) - Possible Cures

Train operators

Use correct ladle size

Do not use launders


Issue (1) - Possible Actions Required for Cures:

D/C Foreman to train operators on proper pouring techniques

Jerry Brown to add "Do Not Use Launders" on Work Instruction and Set-Up Sheet


Issue (2) - Possible Cures:

Square machine at each set-up

Do Not to run machine when die is spitting

Check for other issues before squaring the machine, ie check tie bar nuts, flash, etc.

Put key switches on die height adjustment


Issue (2) - Possible Actions Required:

Jerry Brown to modify Set-Up sheets to show machine to be squared at each set-up

Jerry Brown to modify Work Instruction to show NOT to run machine when die is spitting

John Howze to make a checklist for things to do before squaring the machine

John Howze to talk to Jimmy to see if we can put key switches on die height adjustment


Subordinate:

All actions need to be completed prior to the next run. The next run will be sometime this month

ALL TEAM MEMBERS WILL MEET AT THE MACHINE FOR THE NEXT SET-UP


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