Process Optimization
Process Optimization
Process selected Grinding
Plant G.N.A Udyog Ltd.
Name of the Leader Deepak Thakur
Team Members Mr. Raj Kumar
Mr. Jatinder
Mr. Sukhdeep
Mr Subhas
Date of Start 25th Aug09
Slide number:
1
Process Optimization
P
Planning
PLANNING
A
ANALYSE
Analyse
I
Improve
IMPROVE
C
Control
CONTROL
Slide number:
2
Process Optimization
Phase – 1- Planning
No. Parameter
1 Process selected Grinding
2 Part number selected for I. Shaft
study
3 Machine selected for study GY-02
4 Other similar part numbers PSA Teeth
where the optimal setting can
be deployed
5 Responses Description Type of response Specification
(Var/Att )
Ra Value Variable 0.63 max
Slide number:
3
Process Optimization
Phase – 1- Planning
Project Planning
Month Month Month
Phase
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
Plan
Analyze
Improve
Control
Phases Planned Start Planned Actual start Actual Status
date Completion date completion
date date
Plan 25 Aug 09 12 Sept 09 27 Aug 09 10 Sept 09 Complete
Analyze 13 Sept 09 25 Sept 09 14 Sept 18 Sept 09 Complete
Improve 26 Sept 09 10 Oct 09 29 Sept 09 9 Oct 09 Complete
Control 10 Oct 09 20 Nov 09 10 Oct 09 29 Oct 09 Complete
Slide number:
4
Process Optimization
Phase – 1- Planning
Photograph of the part
Response ( Y )
Response Y = Ra Value
Specification : 0.63 Max.
Slide number:
5
Process Optimization
Phase – 1- Planning
Design Parameters identified for Optimization
A – Cutting Margins
B – Dressing Frequency
C – Straightening
Slide number:
6
Process Optimization
Phase – 1 – Planning
No Parameter ( - Setting ) ( + Setting )
A Cutting Margins 0.5 0.30
B Dressing Frequency 10 15
C Run out/Straightening 0.15 0.10
Slide number:
7
Process Optimization
P
Planning
PLANNING
A
ANALYSE
Analyze
I
Improve
IMPROVE
C
Control
CONTROL
Slide number:
8
Process Optimization
Phase – 1 – Planning
No Parameter ( - Setting ) ( + Setting )
A Cutting Margins 0.5 0.30
B Dressing Frequency 10 15
C Run out/Straightening 0.15 0.10
Slide number:
9
Process Optimization
Phase – 2 – Analyze
Step -1
Test - Setting + Setting
1st Run 0.33 0.43
2nd Run 0.40 0.44
3rd Run 0.38 0.54
Median
Range
D ( Difference Between Two
Medians )
d = Average of Two Ranges
D/d
Slide number:
10
Process Optimization
Phase – 2 – Analyze
Step -1
Conclusion:
Slide number:
11
Process Optimization
Phase – 1 – Planning
No Parameter ( - Setting ) ( + Setting )
A Cutting Margins 0.20
B Dressing Frequency 20
C Run out/Straightening 0.08
Slide number:
12
Process Optimization
Phase – 2 – Analyze
Step -1
Test - Setting + Setting
1st Run 0.40 0.73
2nd Run 0.45 0.63
3rd Run 0.44 0.74
Median
Range
D ( Difference Between Two
Medians )
d = Average of Two Ranges
D/d
Slide number:
13
Process Optimization
Phase – 2 – Analyze
Step -1
Conclusion:
Slide number:
14
Process Optimization
Phase – 2 – Analyze
Step -1
Median(+)
Median(-)
Average of Medians
d
1.45*d
1.45*d (after rounding off to the same
decimal place as data. Always round
off to higher number)
UDL(+) = Median(+) + 1.45*d
LDL(+) = Median(+) – 1.45*d
UDL(-) = Median(-) + 1.45*d
LDL(-) = Median(-) – 1.45*d
Slide number:
15
Process Optimization
Phase – 2 – Analyze
Step -2 – Method #1 data collection
Is the
contribution
- Setting + Setting Average UDL (+) LDL(+) UDL (-) LDL(-) Conclusion zero
1st
run 0.40 0.73
2nd
run 0.45 0.63
3rd
run 0.44 0.74
A 0.65 0.73
B 0.53 0.42
AB 0.73 0.41
Slide number:
16
Process Optimization
Phase – 2 – Analyze
Step -2 – Method #1 data collection
Graph
Slide number:
17
Process Optimization
Phase – 2 – Analyze
Step -3 – Factorial analysis
Factorial table
Response Median Is there any parameter
held at a specific setting
because its contribution
is not zero Yes
If yes, what are the
parameters and what are
the settings
-Not Aplicable
-
-
-
Slide number:
18
Process Optimization
Phase -2 Analyze – Step # 4 – Factorial plots
Coefficients in actual value for making equation
Slide number:
19
Process Optimization
Phase -2 Analyze – Step # 6 – Optimization
Objective of Y Higher better/ Lower better / Nominal better
Upper boundary of Y
Lower boundary of Y
Nominal value of Y
Slide number:
20
Process Optimization
Phase -2 Analyze – Step # 6 – Optimization
Optimal Settings identified using equation
Slide number:
21
Process Optimization
Phase -2 Analyze – Step # 6 – Optimization
Optimal Settings identified using equation
No Parameter Current setting Optimal setting
A Cutting Margins
B Dressing Frequency
C Run out/Straightening
Slide number:
22
Process Optimization
P
Planning
PLANNING
A
ANALYSE
Analyze
I
Improve
IMPROVE
C
Control
CONTROL
Slide number:
23
Process Optimization
Phase – 3 - Improve
Validation using B vs C
1 Part number selected for validation I.Shaft
2 Better Condition Revised Parameter
Current Condition Existing parameter
3 Sample size 3B,3C
4 Sample type Pieces/Batches
5 Response decided for monitoring Ra Value
6 Lot quantity (for batches) 20
Slide number:
24
Process Optimization
Phase – 3 - Improve
Data obtained during validation
Piece / Lot Better ( B ) Current ( C )
1 0.36 0.42
2 0.37 0.54
3 0.40 0.53
D/d
Slide number:
25
