SPEAKER SPEAKER • Chemical Engineer • Nearly 40 years experience in the industry in various fields (R&D, support, sales, etc.) Luc Nelen
STEP-BY-STEP PROCESS IMPROVEMENT Luc Nelen luc.nelen@innosen.com
AGENDA • Introduction • Basics of Process Improvement • Fault-Mode Effective Analysis (FMEA) • Examples of FMEA and solutions • Conclusion
WHY? WHAT? HOW?
https://www.innosen.com/tours/3pc/
Make a Sensitivity Analysis - Estimate effect of errors in assumptions INTERNAL RATE OF RETURN (IRR) space DEVIATION
PRODUCTION QUALITY & Can Quality QUANTITY Both important
No quick fix Many small steps No easy Shortcuts!
IMPROVEMENT PROCESS Measure Compare with Target Correct
Measure and figure out the corrective action
MEASURE • Repeatability & Reproducibility (R&R) • Can I trust my measurement? o Operator o Equipment
Repeatability and Reproducibility (R&R) • Repeatability measures the variation in measurements taken by a single person under the same conditions • Reproducibility measures whether measurements can be reproduced by different people etc.
HOW TO IMPROVE?
Fault-Mode & Effect Analysis (FMEA) • Work backwards to find solution • Effect → Cause
FMEA EXAMPLE FMEA FOR LACQUERING LINE D Risk Responsibilit Potential S Potential O Current Acti- Potential Detection Priority Criticality Recommended y & Target Function Effect of Severance Cause of Occurrence Process on re- Failure Rating Number (S-O) Actions completion Failure 1 – 10 Failure 1 - 10 Controls sults 1-10 * (S-O-D) date Lacque- Unlacquered Blunting of Lacquer tank ring 9 3 None 5 135 27 Sheets press tooling starvation Sheets Unlacquered No double cans getting Fit double sheet sheet Double Sheet to customer - detector and detector 10 Detector 1 90 90 Customer missing lacquer fitted Fitted complaints detector and claims Loss of Double sheet Rely on Install customers detector not operator’s auto-calibrating 7 9 567 63 due to adjusted judgement double sheet quality issues correctly detector Rely on Install double Double sheet operator sheet detector detector not 2 6 108 18 detecting with "heartbeat" working malfunction output Conveyor and oven Rely on speed not operator Install additional synchronized seeing it double sheet or causing 4 happen and 6 216 36 missing lacquer sheet to flip take out detector after over and faulty sheets the oven stick to from oven another sheet *1-Detected 10 - Not Detected
Measure and figure out the corrective action
IS231 Double Sheet/End Detector A sensor that calibrates automatically True “Fit and Forget” No operator intervention, no risk of wrong adjustments Large thickness range (0.08 - 1.6mm / 0.0031” – 0.063”) Works on both aluminium and tinplate For use on coating and printing lines, slitters and presses etc.
IS651 Missing Lacquer Detector Protects machinery and product against problems caused by missing lacquer on blank sheets. No need for operator adjustment Self‐adjusting and self‐calibrating Works with all white, coloured AND CLEAR LACQUERS Protects your equipment and your reputation from expensive quality issues Typically installed before/after the oven on coating lines or on press infeed
FMEA EXAMPLE FMEA FOR LACQUERING LINE D Risk Responsibility Potential S Potential O Current Acti- Potential Detection Priority Criticality Recommended & Target Function Effect of Severance Cause of Occurrence Process on re- Failure Rating Number (S-O) Actions completion Failure 1 – 10 Failure 1 - 10 Controls sults 1-10 * (S-O-D) date Wrong setup Install skew Lacque- of side measurement Skewed Weld wire Manual ring 5 guides of 3 9 135 15 system IS415 margins breakage supervision sheets coater and/or Margin or slitter inspector IS610 Production Max speed Statistical data Damage to too fast / not based on from IS415 3 7 105 15 weld rolls process margin helps finding uncontrolled quality max speed Microleakers Aestetical quality issues Customer complaints and claims *1-Detected 10 - Not Detected
IS415 Skew Measurement System Full protection from skewed sheets, even at high line speed Highly accurate measurements Increase production quality Achieve faster production rates – without the risk of extra scraps Provides useful statistical data Experience on modern high-speed coating lines shows that up to 1 sheet in every 2000 will skew or misalign badly as it goes through the rollers, no matter how well you control your process!
IS430 Sheet Translation Measurement Adds protection against laterally displaced coating by detecting sheet misalignment at the coater
IS450 Sheet Registration Measurement Adds protection against poor sheet registration by warning of sheet misfeeds at the coater
IS610 Plain Margin Inspector Reliably detects contaminants in the margin of coated /printed sheets. Detects any type of lacquer, even small drops of clear transparent lacquer Detects presence of other contaminants (e.g., grease/oil, rust, water marks) in the margin
Coating Thickness Measurement SI9600 IS9560 IS9650 SI9507+ Easy to use - Highly accurate measurements – World class R&R Wide range of probes for measuring coatings thickness / film weight on flat sheets, cans, aerosols, aluminium tubes, etc.
Enamel Rating SI9100 IS9029 IS9015 IS9021 IS9019TR/IS9020TMR
Enamel Rating IS9030 IS9024 IS9017 IS9029
UV Loggers IS310 IS315
CONCLUSION There are no quick short-cuts in process improvement! It is a step to step process that requires proper analysis to achieve the best result. In this process you require tools in which you can trust, equipment with good R&R and sensors limiting human errors. Innosen offers a large range of products that can help you in this process. Our products are designed for accuracy and ease of use, many of them being fully automatic.
For more information, come see me or Blessie at the exhibition area WE ARE HERE TO HELP YOU
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