Analysis Tecnico

Low VOC's Solvent

Cleaning Process



6σ



A Six Sigma Project Report








By: Manuel Motolinia
Date: May 9 2012
Key Words

6σ. Six sigma symbol created by combining number six and Greek letter sigma.

Cause and Effect or Fishbone Diagram. A visual diagram that allows a team to identify, explore and graphically display with deep detail, all possible causes related toa problem or condition.

CTQ. Acronym that stands for critical to quality. These are characteristics that are specifically related to the quality of a product, service, or a transactional operation which affect the satisfaction of the customer.

KPIV's. Key process input variables are potential sources of variation on a process. Also, they can be defined as potential input variables thatcan influence the mean of the process output.

Non-Value-Added. Non-value-added is a term created by Ford Motor Company to describe waste in a process or service. This term can be applied to any type of activity, step or process that does not add any benefit to the customer.

PM. Preventive maintenance is a Ford Motor Company practice to periodically service all equipment at a assembly plant.By periodically servicing a machine, moving parts, equipment, or any type of mechanical component, it prevents failure or any breakdowns

Process Map. A process map is a flow chart that identifies the flow of events in a process. Inputs (x's) and outputs(y's) are identified in each step of the process

Process Step. Process steps are the tasks that transform the inputs of the process into theoutputs of the process.

TCAP PD. Twin Cities Assembly Plant Paint Department

Wash Solvent. Oil-based solvent that has been used on automated painting operation for cleaning paint equipment when changing colors. Solvent is collected and used for floor cleaning operations.

x's. Inputs that are the key process variables that are required to perform a process steps. Inputs could includepeople, methods, materials, machinery, measurements, or environment.

Y=f(x). A mathematical symbolic equation which is used to represent a problem in the Six Sigma methodology. Y is the problem and x is the solution(s).

y's. Outputs are key variables resulting from the performance of the process step, outputs can be goods, services, measurements or consequences.

Table of Contents

KeyWords.....………………………………...…………………….……….…….……………2
Executive Summary………...…………………………………………………………………4
Research Plan.…………………………………………………………………………………6
Six Sigma Methodology.....…………..………………………………………………7
Define Phase…………………….………………………………………………7
Measure Phase………………….………………………………………………8
Analyze Phase……………….………….……………………………………..10
ImprovePhase……………….…….…………………………………………..11
Control Phase…..…………….……………………………….……………….14
Conclusion.....………………………………...…………………….………….…….……….17
References.....…………………………………...………………….………….….………….18
Appendix.....……………………………………………………….……………….………….19
First Brain Storming Session Questionnaire.……………………………….19
5 Whys Tool Survey……….......…………..………………………………….20
LessonsLearned….……….......…………..………………………………….23
Executive Summary

The goal of this report was to find an efficient cleaning process and an environmentally friendly cleaning product for the current oil-based solvent used at the TCAP PD.

TCAP PD was using excessive oil-based solvents in order to clean paint sludge on the inside and outside of the painting booths. Paint sludge is the result of an accumulation of overspraying paint inside the painting booths during paintingoperations. New guidelines have been implemented to minimize foot prints from paint sludge when entering and exiting the painting booths. However, there were areas where cleaning was not to be compromised: the flooring outside the booths, paint build-up on the equipment inside, and overspraying inside the booth windows. These...