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SHD COVER SCRAP PROBLEMSSeptember 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 |