1. Information is Tyco Electronics Confidential & Proprietary
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Kaizen Event : UC Squib Productivity Improvement and
Reduction in Rejection.
Team Leader:Deepak(ME).
Team members: Kiran (Prod), Rajesh (ME), Prasad (Tool Main), Paramesh (Prod)
Date : 18th
March 2010

2. page
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Base line
Metric Baseline Target Improvement
Cycle Time 54 sec 40 sec 26%
Rejection
percentage
12% 4% 67%
Mold down time 6.3 hrs/month 1 hr/month 84%

3. page
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PRODUCT OVER VIEW
UC squib is used in air bag application. It is used for secure connection of the
airbag ignitor via the cable harness to the airbag control box.
We produce around 39 pn according to different lengths and cables.
Customer:-
Autoliv,Takata,Filec.

4. page
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Why this project?
• Increase in customer demand.
• The daily machine capacity was 7500nos
• Customer escalation regarding delivery
• High scrap percentage.

5. page
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Pareto Analysis
Rejection
reasons Qty Percentage
Material
entry 13636 39.81
Flash on
cable 4735 13.82
Rough finish 3970 11.59
Flash on
contact 3642 10.63
Incoming
problem 2969 8.67
Short shot 2584 7.54
Contaminati
on 1343 3.92
Contact
visible 726 2.12
Contact
height
variation 352 1.03
Cable
damage 296 0.86
Paretoforrejectionqty
39.81
53.63
65.22
75.86
84.52
92.07
95.99 98.11 99.14 100.00
0
2000
4000
6000
8000
10000
12000
14000
16000
Materialentry Flashoncable Roughfinish Flashoncontact Incoming
problem
Shortshot Contamination Contactvisible Contactheight
variation
Cabledamge
Reasons
Qty
0.00
20.00
40.00
60.00
80.00
100.00
120.00

6. page
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Action Plan
Major Problem Causes Corrective action proposed
Material entry Gap between ferrite and contact.
Narrow process window .
Delay in cycles.
Optimizing the cycle time.
By increasing mold open/Close speed,
By increasing nozzle advance/retraction speed.
Rotary table speed.
Adding one more operator station for part removal.
Flash on cable Improper placement.
Narrow process window.
Imbalance in filling.
Training to operators .
Optimizing the cycle time.

7. page
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Action Plan
Major Problem Causes Corrective action proposed
Rough finish
Drooling
Delay in cycle
Narrow process window.
Imbalance in filling.
Optimizing the cycle time
Flash on contact Delay in cycle
Narrow process window.
Imbalance in filling.
Optimizing the cycle time

8. page
Information is Tyco Electronics Confidential & Proprietary
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Action plan
Burn
mark
No air
vents
Air vents
provided
Before After Before After
Cable insertion
Nozzle Retraction speed (%):-25
Nozzle retract stroke(mm):260
Delay time (sec):-15
Nozzle retraction
Nozzle Retraction speed (%):-
40
Nozzle retract stoke(mm):223
Delay time (sec):-2
Speed(%):-35
Rotary table
movement
Speed(%):-50 Opening speed(%):15/40/20 Mold opening Opening speed(%):15/40/20
Closing
speed(%):15/20/15
Mold closing
Closing
speed(%):35/45/1
5
Speed(%):-35
Rotary table
movement
Speed(%):-50
Nozzle advance speed
(%):-50/15
Nozzle advance
Nozzle advance
speed (%):-50/15
Cable removal
Injection

9. page
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Action Plan
• One more stage for manpower added for part removal and insertion
instead of one person doing it.
• Training for all UC Squib operators as per WI.
Before After

10. page
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Benefits
• Productivity Improvement.
• Efficiency improvement
Daily output
9065
12545
0
2000
4000
6000
8000
10000
12000
14000
Before After
Qty
Efficiency
155
110
127
138
0
20
40
60
80
100
120
140
160
180
November December January Febraury
Month
Eff

11. page
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Benifits
Rej PPM
9 0 3 3 2
3 8 2 55
3 4 571
4 2 72 1
0
10000
20000
30000
40000
50000
60000
70000
80000
90000
100000
November December January FebruaryMonth
PPM
• Reduction in rejection.
• Mold down time reduced from 6.3 hrs to 1 hr.

12. page
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Benefits and Next Action Plan
Savings ($) December January February
3547 4038 4446
Next Action Plans
• Replacing the injection unit with nozzle shut of unit.
• Working on Visual inspection stages .

13. page
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Thank you