Lean Six Sigma Green Belt

Final Project Report-Out

Throttle Body Assembly Line Balancing

Duration of Project:

June 11, 2004 to September 27, 2004

Team Membership

• Business Unit Manager

• Shift Supervisor
• Scheduler/Planner
• Intern Engineer
• Process Owner

1
Define

• The Throttle Body Assembly Process requires the

assembly of various tubes, shafts, plates, springs,
levers, and fasteners into machined castings.
Input Process Output Diagram

INPUTS PROCESS OUTPUTS

(Source of Variation) (Measures of Performance)
People, Material, Equipment, Accuracy, Timeliness, Cost
Policies, Procedures, Methods,
Environment

Process Name

Human Effort/Pride Direct Labor Costs/Benefit Costs

Throttle Body Assembly
Planning/Info./Schedule Customer loyalty-Dissatisfaction

Machined TB Castings Material costs(tubes, plates, shafts

Machinery, Equipment, Tooling Process Description Subassembly for Final Assy.

Training Revenue / Sales

Assemble throttle shafts, plates,
Product and process knowledge tubes, idle adj, and test. FPY

Electricity/Power Finished Goods& WIP Inventory

Systems /Procedures

purchased components (plates)

2
Define

• Problem Statement (description)

– The current assembly process does not perform to acceptable
cost levels.

• Project Goals
– Reduce Labor Costs by 20%
– Achieve 99 % FPY
– Reduce WIP 20%

3
Define Current State Process Map

Start Value Added

A B

Element # 8 Element # 16
Insert 8 screws, Assemble Pump Lever
connect rod w/ power and e-retainer and
Element # 1 screw driver and aside. aside
Apply Loctite to
stud hole.
Element # 9 Element # 17
Fasten 8 screws and Get assy, insert in Element # 18
aside. fixture, engage PRI slot Check PRI and SEC
saw, blow, unclamp & slots with depth Gage.
Element # 2 aside. (1 per 20 pcs)
Ream throttle Element # 10
Body & Aside. Assemble carter key
and connecting rod,
tighten carter key and
aside.
Pass or
Reset saw height
Element # 3 Fail?
Scrap Assembly
Stamp ID #, Insert
Element # 11
SEC air, inser
Insert casting in fixture,
stud and aside.
cycle, turn, cycle
(staker).

Element # 4 Element # 12
Get casting Place in fixture 1, cycle, Stage for Final
Fasten idle air screw
Reload Booster/Vacuum tube (14R486R) Assembly or
with pneumatic driver..
in press. Get casting from fixture 1 Place Service Kit.
in fixture 2, cycle, Reload spark tube.
Insert Idle Air Screw.

Element # 19 Element # 5
Element # 13
Set part in fixture, Inferences:
Get shaft and lever and Insert 46R1323 ring, 38R2354 clamp, get screw and
preassemble, insert in
fixture,cycle, & aside.
spring, 28R135 ball, 20R714
ring, cycle mach., and aside.
bracket (4R485),
preassemble and fasten
with pneumatic driver.
• Move off-line operations in-
Element # 20 Element # 6
Get casting, Insert SEC Element # 14
line.
Get shaft and lever and
insert in tube/fixture
apply 4 bushings and
aside.
Shaft, and Secondary
Throttle Plates (x2) and
Aside.
Get screw & 63R354A,
preassemble to throttle
body, get pneumatic
and fasten and aside.
• Eliminate PRI & SEC Slots.
Element # 7
Element # 21 Element # 22 Insert PRI throttle Element # 15
Assemble cam to big Get shaft lever, shaft and PRI Get Assy., place in test
lever (with screw) & bushing, spring, big throttle plates (x2) fixture, cycle & unclamp
aside. lever, assemble, set in and aside. and aside.

A B

4
Measure - Value Stream Map

Inferences:
• The number of throttle
body Assy. operators = the
number of final assy.
Operators.
• Excessive WIP
•Low VA time.

5
 Measure - Current Work Load Distribution & Work Sampling
Current Throttle Body Assembly Load Leveling Chart
(13 Work Stations)

0.6000
Takt = 0.54

VA vs. NVA Observations

0.5000

Total Value
0.4000
Added
45% Observations
Minutes

0.3000

55% Total Non- Value

0.2000
Added
Observations
0.1000

0.0000
1 2 3 4 5 6 7 8 9 10 11 12 13
Process Delay/Over Production Work Stations
Element 3
Element 2
Element 1

Inferences: Inferences:
• Balance effort. •Retrieve materials.
• Combine operations. •Idle.
•Sorting.
6
Measure

• Baseline Data

• FPY and Sigma Capability

Throttle Body Assembly

Product Sum m ary Report

Total Sigm a FPY

Characteristic Defects Units Opportunities Opportunities DPU DPO DPMO Capability 97%
1 222 7895 1 7895 0.02812 0.02812 28119.063 3.4092

7
Analyze Fishbone Diagrams
Measurement Method Machine

Takt Off line vs. In- Additional

Small Batch/Big
PC Count/Stamper Batch Additional Drivers

Produce to Additional
Closed Throttle/PSI Takt/Balance Bins/Tables

Check Light/Throttle Relocate

Plate Assy. Materials Sec/PRI Slots

Transporting
Forecast PCS to Main Reamer

Swivel Chairs Layout

Labor $/Unit

Mature Machined
Workforce Castings Heat

Cross Sec Shaft

Training/Skills Wraps Noise

Fixed Team Throttle Plates Lighting

Manpower Materials Environment

8
Improve – Work Load Distribution

• Work Loading Based on Takt Throttle Body Assembly Takt Time Calculation
Daily Requirements
0.6000

0.54
Final Assembly 650
0.5000
Service 58
Total Daily Requirements 708

0.4000

Hours Available/Shift 8
Minutes Available/Shift 480
Minutes

0.3000
Number of Shifts 1
Total Available Minutes/Day 480
0.2000 Breaks & Clean-up/Day (Min.) 30
Change-Over Time (Min.) 20
Total Available Production Minutes/Day 430
0.1000

Takt Time (Total Available Production Minutes/Daily Requirements) 0.60734

0.0000 Leveled Takt Time (90%) 0.54661
1 2 3 4 5 6 7 8
Work Stations

JOB 1 JOB 2 JOB 3 Proces s Delay/Over Production

9
Improve
Throttle Body Assembly Process Map
Work Station 1 Work Station 2 Work Station 3 Work Station 4 Work Station 5 Work Station 6 Work Station 7 Work Station 8

Start

Element # 4
Get casting Place in fixture 1, cycle, Element # 5
Element # 6 Element # 7 Element # 11 Element # 14
Element # 1 Reload Booster/Vacuum tube (14R486R) Insert 46R1323 ring, 38R2354 Element # 9
Get casting, Insert Insert PRI throttle plates Insert casting in fixture, Get screw & 63R354A,
Apply Loctite to in press. Get casting from fixture 1 Place spring, 28R135 ball, 20R714 Fasten 8 screws and
preassemble to throttle
JOB 1 stud hole. in fixture 2, cycle, Reload spark tube. ring, cycle mach., insert sec
throttle shaft and aside.
Secondary Throttle Plates
(x2), and PRI shaft and
(x2) and aside. aside. cycle, turn, cycle
(staker). body, get pneumatic
Insert Idle Air Screw.
aside, and Aside. and fasten and aside.

Element # 2 Element # 8 Element # 15

Insert 8 screws, connect rod Element # 10 Element # 12
Ream throttle Element # 19 Element # 20 Get Assy., place in test
Element # 22 w/ power screw driver and Assemble carter key Fasten idle air screw
Body & Aside. Get shaft and lever and Get shaft and lever and fixture, cycle & unclamp
JOB 2 Start preassemble, insert in insert in tube/fixture Get shaft lever, aside. and connecting rod, with pneumatic driver..
and aside.
fixture,cycle, & aside. apply 4 bushings and bushing, spring, big tighten carter key and
aside. lever, assemble, set in aside.

Element # 3 Element # 16
Element # 21 Element # 13 Assemble Pump Lever
Stamp ID #, Insert Assemble cam to big
Start Set part in fixture, and e-retainer and
SEC air, inser
JOB 3 stud and aside.
lever (with screw) &
aside.
clamp, get screw and
bracket (4R485),
aside.

preassemble and fasten

with pneumatic driver.

Stage for Final Assembly or

Service Kit.

Kaizen Activity Time Line

Completion DATE Event Event Event Event Event Event Event Event

8/13/2004 Relocate SEC Radial Bracker To Main Line Relocate Bushing Wrap Fixture

8/16/2004 Construct Cam/Lever Assembly Fixture.

Construct Gravity Bins to transport

8/16/2004 Throttle Shaft Assembly.

Eliminate Batch Ream, Blowing, Construct Gravity Bins to transport

8/18/2004 and Loctitie. Throttle Shaft Assembly.

Relocate PRI Radial Bracker To Install Table to Accommodate PRI

8/19/2004 Main Line Throttle Plate Assembly.

Modify Fastening Station/Fixture to

8/22/2004 accommodate the Carter Key
Assembly.

Reposition Staker and Lever (4R485)

8/23/2004 assembly fixture for one person
workstation.

Construct Gravity Bins to transport Construct and install fixture to Assemble

8/24/2004 Subassembly. SEC throttle Lever. Tool # 12R-10072A-3-F1)

10
Improve

• Verification of Improvement
– Labor Cost Unit:
Direct $ Labor/Unit Dept. 1203
Direct $/Unit
$4.50
$4.00 $3.87
Linear (Direct $/Unit )
$3.50
$3.00
$2.50 $2.53
$2.35 $2.33
$2.07 $2.09 $2.11
$2.00 $1.89
$2.04
$1.77 $1.84
$1.70 $1.64
$1.50 y = -0.0891x + 2.7884
$1.45

$1.00
$0.50
$0.00 2004 2004 2004 2004 2004 2004 2004 2004 2004 2004 2004 2004 2005 2005

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb

11
 Control

• Control plan
Control Plan
Process Name: Throttle Body Assembly Line Prepared by: Howell Hopper Orig Date: 9/13/2004
Process Owner: Bart Brashear Approved by: Revision Date:
Customer: Core Team:

Performance Indicators KPIV Requirements (Target, Msmt. Method Reaction Plan

Departments Process Step (Description) KPOV specs) Sample Size Sample Size Frequency Who? Record Location (corrective action) SOP Ref.
Morris Rogers (1203
1203 Assy. Crew Size 9 Direct Hours Days Production Daily N:Drive Re-balance CP-2002
Sup.)
Non Defective
Howell Hopper &
1203 Assy. FPY 99% Units (Physical Days Production Daily N:Drive Define Problem/Pareto PCI's
Jerry Taylor (QC)
Count)

12
Control PCI’s

13
Project Summary Scorecard … before and after

CHANGE ANNUAL
METRIC BEFORE AFTER SAVINGS
(%)

UNIT LABOR
$2.78 $1.53 44% $198,106
COST $

FPY 97% 99% 2% $20,603

WIP 662 513 23% $0

TOTAL - - - $218,709

14
Project Summary

• Problem
– The current assembly process does not perform to acceptable cost
levels.

• Baseline and Target Performance

– Reduce Labor unit cost 20% (Baseline: = $2.78 Target : $2.22)
– Improve FPY from 97% to 99%
– Reduce WIP 20% (Baseline WIP: 662 Target WIP:574)

• Analysis and Solution

– Workstation loading analysis revealed that it was possible to compress 13
workstations into 8 (at 650 pcs/day).

• Results and Business Benefit(s)

– Unit Labor Cost was reduced from ($2.78 to $1.53) = 44%
– FPY was increased to 99%
– WIP was reduced from 662 to 531.
– Annual Savings $218,709

15
Appendices … Additional Supporting Material

• Before Improvement Video

16
Appendices … Additional Supporting Material

• After Improvement Video

17
Appendices … Additional Supporting Material

• Before and After Physical Process Maps

⌧ C urrent Throttle B ody
⌧

A ssem bly Layout

X II X III
E lem ent 21

E lem ent 20 Elem ent 19 E lem ent 22

⌧

XI X IX V III V II
E lem ent 13
E lem ent 14 E lem ent 11
V I V IV III II I
E lem ent 12

Elem ent 1
E lem ent 17 Elem ent 15
Elem ent 18 Elem ent 16 E lem ent 9 Elem ent 8 E lem ent 7 Elem ent 5 E lem ent 4 Elem ent 3 E lem ent 2
E lem ent 10 E lem ent 6

⌧ Proposed Throttle Body

⌧

Assembly Layout

VIII
Element 16
VII
Element 13
VI V IV III II I Element 1
Element 15 Element 12 Element 9 Element 7
Element 4
Element 14 Element 11 Element 10 Element 8 Element 6 Element 5 Element 2
Element 22 Element 22 Element 20 Element 19 Element 3
Element 21

Eliminated
Element 17
Element 18

18
Appendices
Product or Process Failure Mode
Apply Loctite to Stud Hole Loose or Backed out Stud
Ream Throttle Body & Aside. Hole not Reamed
Stamp ID #, Stamp SEC air, insert stud and aside. No SEC air.
No Stud
Incorrect Assy. ID
Get casting place in fixture, cycle, Reload
Booster/Vacuum tube in press. Get casting from fixture
No Tubes
1 place in fixture 2, cycle, Reload spark tube. Insert Idle
air tube.
No idle air screw.
Insert ring, spring, ball, ring, cycle mach. and aside. Wrong parts/No parts.
Wrong shaft or damaged
Get casting insert SEC shaft and SEC throttle plates
shaft. Wrong plate or
(x2) and aside.
damaged plate.
Wrong shaft or damaged
Insert PRI throttle shaft and PRI throttle plates (x2) and
shaft. Wrong plate or
aside.
damaged plate.
Insert 8 screws with power screw driver and aside. No screws.
Screws too tight or too
Fasten 8 screws.
loose.
Assemble cotter key and connecting rod key and aside. Wrong connector.
Damaged connector.
Missing connector.
Insert casting in fixture, cycle, turn, cycle staker. Miss staking operation.
Fasten idle air screw with pneumatic. Improper setting.
Set part in fixture, clamp, get screw and bracket, pre-
Damaged Bracket.
assemble, fasten with pneumatic.
Missing Bracket.
Get screw, pre-assemble to throttle body, get
Damaged Bracket.
pneumatic, and fasten, and aside.
Missing Bracket.
Get assembly, cycle in test fixture, cycle and unclamp. Defect not detected.
Remove assembly pump lever and e-retainer and
Damaged Lever.
aside.
Wrong. Lever.
Missing Pump lever and sub
assembly component.
Too deep, too shallow, too
Get assembly, insert in fixture, cycle and aside.
long, too short. Burr slots.
Check PRI and SEC slots with depth gage (1/20). Defect not detected.
Get shaft and lever and preassemble, insert in fixture,
Wrong. Lever.
cycle, and aside.
Damaged Lever.
Insufficient brackering.
Get shaft/lever and insert in tube/fixture, apply 4 Bad Bushings (too thick or
bushings, and aside. split)
Insufficient brackering.
Assemble CAM to big lever (with screw). Wrong parts.
Mislocated Screw.
Get shaft, lever, bushing, spring, big lever, assy, set in
Wrong Lever
fixture, cycle, and aside.
Damaged Lever
Insufficient brackering.
Assemble CAM to big lever (with screw).
FMEA
p
S O D R
P P P r
Failure Effects E Causes C Controls E P Actions Plans
S O D p
V C T N
n
No Pump. Pump Lever Oper. missed stud hole (batch).
2 1 1 2
Binding. Not enough loctite.
No SEC Shaft opening. Shaft Oper. missed part. Manual
2 2 1 4
Binds. NCT. alignment.
Poor Idle 2 Oper. missed operation. 1 1 2
Closed Idle 2 Missed. No Loctite. 1 1 2
Assy. Rework. 2 Missed. Die Dull. 1 1 2
Oper. missed or improperly
Vacuum Leak/No Flow 2 3 3 18
inserted.
Oper. missed or improperly
can't set curb idle. 2
inserted. 2 2 8
Back Fire/Blow out power Oper. missed or improperly
4
valve. inserted. 1 3 12
Damaged a vendor or during
Shaft Binds. NCT. 2 3 2 12
shipping/handling.
Damaged a vendor or during
Shaft Binds. NCT. 2 3 2 12
shipping/handling.
Oper. missed or improperly
Plates fall out. 2 1 1 2
inserted screw.
Insufficient Torqur/too much
Fast Idle lever. 2 3 2 12
Torque.
Part mis-identified or improperly
NCT/SEC wide open. 2 3 3 18
referenced.
Not inspected or damaged
NCT/SEC wide open. 2 2 2 8
during handling.
Oper. missed or improperly
NCT/SEC wide open. 2 2 2 8
inserted.
Screws fall out and drop in Oper. missed or improperly
5 1 1 5
engine. inserted.
Oper. missed or poorly
NCT binding. 2 1 2 4
fastened.
Not inspected or damaged
NCT binding. 2 3 1 6
during handling.
Oper. missed or poorly
NCT binding. 2 3 1 6
fastened.
Not inspected or damaged
NCT binding. 2 3 1 6
during handling.
Oper. missed or poorly
NCT binding. 2 3 1 6
fastened.
Improper sealing, bad throttle
NCT. 2 1 5 10
plates, bend shaft, etc.
Shipping/Handling not properly
No conformity to flow spec. 2 2 2 8
inspected.
Part mis-identified or improperly
No conformity to flow spec. 2 3 2 12
referenced.
Oper. missed or poorly
No conformity to flow spec. 2 fastened. Not inspected before 3 2 12
assembly.
Manual location for sawing.
Poor idle. Poor Flow. 2 3 3 18
Poor fixture/machine/method.
Poor idle. Poor Flow. 2 Random Testing. 3 5 30
Part mis-identified or improperly
NCT. 2 4 2 16
referenced.
Material handling method. Not
NCT. 2 2 1 4
inspected before assmebly.
Lever comes loose in field.
3 Improper Set-up. 2 2 12
Warranty.
Loose bushings. Rework. 2 Poor quality from vendor. 1 1 2
Lever comes loose in field.
3 Improper Set-up. 2 2 12
Warranty.
Part mis-identified or improperly
Insufficient pump. 2 2 2 8
referenced.
Oper. Improperly
Insufficient pump. 2 2 2 8
located/inserted.
Part mis-identified or improperly
NCT. 2 4 2 16
referenced.
Material handling method. Not
NCT. 2 2 1 4
inspected before assmebly.
Lever comes loose in field.
3 Improper set-up. 2 2 12
Warranty.
19
Appendices Pareto
Dept 1203 FPY Pareto Analysis

50

45

40

35

30
Total Defects by Category
Defects

25 Total Dept 1203 Throttle Body Defects

20

15

10

0
No Airflow Fast Idle Pump Stud Wrong No Fast Stop Lever Wrong
Screw Lever Not Down Fast Idle Idle Lever on SEC Linkage
Misloacted Lever Shaft
Mislocated

20