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2008 Kaizen Challenge

2008 Kaizen Challenge. Pyeongtaek, Korea. John Lee, maintenance engineer June Park, quality engineer James Yoon, manufacturing engineer. Kaizen Challenge. Plant Profile: Pyeongtaek, South Korea. Establishment : Aug.2002 Land/Floor space : 28,328 m 2 /6,209 m 2

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2008 Kaizen Challenge

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  1. 2008 Kaizen Challenge Pyeongtaek, Korea John Lee, maintenance engineer June Park, quality engineer James Yoon, manufacturing engineer

  2. Kaizen Challenge Plant Profile: Pyeongtaek, South Korea Establishment : Aug.2002 Land/Floor space : 28,328 m2/6,209 m2 SOP : Oct. 2004 Products : Theta BSM, Tau FEMA Production : 292,690 units in 2007 Sales in 2007 : USD $36,206,000 : 3,835,663,640 JPY Employees : 62 Current Products: Future Products: Customers: Kaizen BSM for Hyundai R-Eng FEMA for Hyundai Tau-Eng BSM for Hyundai Theta-Eng IP Damper for Hyundai R-Eng

  3. Inertia Inertia Centrifugal Centrifugal force Centrifugal force Centrifugal Centrifugal force Balance weight Inertia What Does a Balance Shaft Module (BSM) Do? • ☞ Engine Vibration 1: Crank shaft rotating • ☞Engine Vibration 2: Balance weight rotating Balance weight is attached to reduce crank vibration The BSM offsets the balance weight • ☞ BSM function • ☞ Engine & BSM • Theta BSM ■ Engine oil pumping system with two oil pumps ■ Reduces engine second vibration with balance shaft

  4. Problem Identification from 2007 MOS

  5. Reasons for High Process PPM in 2007

  6. Potential Areas of Defect ‘A’ Value ‘B’ Value ‘C’ Value

  7. Kaizen Team Members NVH Machine operator Maintenance Engineer (Leader) Purchasing & Tool room man Electrician Quality engineer Manufacturing engineer Mechanic

  8. Mfg Mfg Eng Quality BSM Vibration Cause Analysis Before KAIZEN Machine Method KAIZEN Team ‘C’ Value Fault Man Material

  9. BSM Vibration Cause Analysis After KAIZEN Machine Method Grinding MC Assembly MC Testing Time NVH tester Environment Timing belt system Oil input volume Improper sensor position Low clamping force ‘C’ Value Fault Improper Loading Improper component material Bad parts mixed with good Componentout of spec Missed operation Parts cleanliness Man Material

  10. NVH R&R History Background of NVH Kaizen Activity Target Under 10% NVH ‘C’ value was not achieving our goal. Beginning in April 08, we selected and tried NVH tester modification.

  11. Clamping system Oil supply system Drive system Accelerator Root Cause for NVH tester NVH Tester is composed of four elements NVH

  12. Action #1 Adjust Vibration Sensor 07/05/08 ~ 09/05/08 Action Taken Adjust vibration sensor position Missing original position Insert Ø6 washers at the vibration sensor Cost of Action = 0 KRW

  13. Action #2 Modify Timing Belt System 01/06/08 ~ 20/06/08 Action Taken Slipping timing belt Change timing belt There is no block for belt tension Cost of Action = 250,000 KRW Add timing belt tension block

  14. Action #3 Improve Clamp Method & Force 21/06/08 ~ 30/06/08 Action Taken Change the clamp arm type Install air booster NVH Tester Low Clamping force Change the pin inner spring Add the clamp cylinder bolt washers Cost of Action = 1,005,000 KRW

  15. Kaizen Results Trend of ‘C’ value fault ( 01/01/08 ~ 14/09/08) Trend ACTION #3 ACTION #2 ACTION #1 ▶The “C” value was significantly improved after Action #1, and deviation decreased after action # 2 and # 3.

  16. Standardization (hadome) for “C” defect Checking master part before production Changed R&R plan from 1 year to 6 months

  17. Standardization (hadome) for “C” defect Added checkpoints in daily visual check sheet (Air pressure, belt wear, sensor position) Visual check sheet Sensor position

  18. Kaizen Results 01/05/08 ~ 14/09/08 Cost Saving 8.7% Millions KRW 8.7% 8.7% 4.5% 8.7% 5.4% 5.0% 8.7% 2.2% 2.5% Total Savings: KRW 34,949,146 (USD$30,389 / ¥3,181,296) Investment Cost: KRW 1,155,000 (USD$985 / ¥105,136)

  19. 8.7% 3.9% ‘0’ Defect Next Kaizen Before Kaizen (Jan - April) Current (May - Sep) Next Kaizen Challenge ‘C’ Defect Rate Gear roll tester Our challenge is to achieve zero defects of ‘C’ fault through continuous Kaizen activity.

  20. Thank you!!!!

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