Coating Tech Slot Dies Process Troubleshooting Six Sigma Presentation June 2014

PROCESS TROUBLESHOOTINGWeb Technology and Six Sigma Methodology

Web Processes & Six Sigma

Define Measure Analyze Improve Control

Six Sigma

DMAIC DFSS 3.4 DPMO Doctrine:

Continuous improvement is critical The process can be measured correctly Buy-in from all stakeholders for improvements ($ v

management timeline)

Define

Definitions Where do the defects come from? Goal & Entitlement Discrete plan – Continuous application Team membership

Define

Define v Design Process map Owners v Changers

Measure

Measure the correct things correctly Examples of variables for coating defects

Web (tension, steering and substrate quality) Fluid delivery (pump variation) Coating head (angle of attack) Curing (method stability) Physics (roll diameters)

“What gets measured gets done.”- Tom Peters

Measure

Discrete (widget) v Continuous (web)

Fluid Substrate Coating Head Curing Measurement systems

Coating Variables

Fluid Downweb variation Flow meters Viscosity Mixers Contamination Air Entrapment Temperature control

Coating Variables

Substrate Downweb & Crossweb variation Know what you are getting Surface energy Web cleaners Steering Tension Temperature control Static

Coating Variables

Coating Head Crossweb variation Air entrainment Attack angle (positioning) Roll TIR “Coating window” Edge effects Temperature control

Coating Variables

Curing Stability Temperature control Time requirement v Extent of cure Effect on substrate Method defects (drying, UV, eBeam, etc.)

Coating Variables

Measurement Systems Incoming substrate Coating head Outgoing web Fluid Crossweb Downweb Machine chatter Continuous?

Analyze

Cause-and-effect Statistics “On board” – Team management Roll example Root Cause

"There are three kinds of lies: lies, damned lies and statistics.”- Mark Twain

Improve

DOE Process journal Human element

Improve

Input changes PET cut example

RTY Hard band defect example

Control

Statistical Process Control Continuous improvement

Summary

Web Processes Variables

Fluid Substrate Coating Head Curing Measurement systems

SummarySix Sigma

Define Define v Design

Measure Correct things correctly

Analyze No wasted effort

Improve DOE

Control Continuous improvement

Thank you

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