PROBLEM

• A global automotive manufacturer recently changed its Pre-treatment and E-Coating material to a less environmentally impacting type which is extremely sensitive to process variation.
• Surface defects requiring a high degree of rework have decreased throughput by 40% and had a negative impact on operational efficiency.
• The high degree of rework created a greater potential for performance failures and warranty issues.

 APPROACH

• Perform an operational assessment (PFMEA) of both internally and externally managed Pre-Treatment and E-Coat processes.
• Include current and future requirements along with critical operational control planning.
• Complete a review of all available manufacturing and quality data (throughputs, rework rate, etc.).
• Use Six Sigma to identify the main issues generating the high volume of rework and develop the Performance Failure Mode and Effects Analysis (PFMEA) for the Pre-Treatment process.
• Develop an implementation roadmap and operational plan using the PFMEA.

SOLUTION

Implement Statistical Process Process Control (SPC) to more closely monitor each stage in the pre-treatment process.  Reduced the range between the upper and lower control limits to ensure greater process control.

Developed a more visual means of identifying normal vs abnormal conditions within each stage.

Implemented a Total Productive Maintenance (TPM) system to ensure equipment reliability as well as process stability.

Developed a Layered Audit Process to ensure compliance with the SPC and TPM systems.  Increased the confirmation frequency and developed visual check / conformation documents for each stage.

Implemented an escalation plan to ensure proper communication of standard conditions.

Redefined the internal and external roles and responsibilities of each team member in the process.

Improved operator knowledge of the process through enhanced training and technical skills.  This was done for both manufacturing operators, technicians and all maintenance personal associated with the process