CTG SIX SIGMA Final.pdf - Chemtool

PURPOSE
• The purpose of this presentation is to
demonstrate the Six Sigma Techniques
and capabilities of the Chemtool, Inc.
Container Technology Group (CTG).
• The presentation follows a typical
aluminum can plant cupper lube trial. The
trial material in this case is NuSol 177-M.
• The tear-off rate during the trial improved
from 0.147/10,000 to 0.128/10,000, a
12.5% improvement.

Was the Tear-off Rate Improvement
Statistically Significant?
• Tear-off rate for seven (7) days
preceding the trial – 0.147/10,000.
• Tear-off rate for seven (7) day trial
period – 0.128/10,000.
Test and CI for Two Proportions (C1A vs. 177M)
Sample X N Sample p
C1A 758 52348754 0.0000147
177M 648 50466446 0.0000128
Difference = p (1) - p (2)
Estimate for difference: 1.639595E-06
95% lower bound for difference: 4.409649E-07
Test for difference = 0 (vs > 0): Z = 2.25
P-Value = 0.012
Yes! The
Improvement is
Statistically
Significant!

Plant Concerns with NuSol 177M
• The following issues typically might be
raised as negatives to NuSol use:
• pH instability
• Tramp oil instability (concentration variation)
• Inconsistent cup lube weights
• Variation in top wall concentricity
These issues are addressed with “data driven”
answers on the following pages.

DID NUSOL 177M IMPROVE COOLANT
pH STABILITY AND CAPABILITY?
• NuSol 177M makes up
at a pH of ~8.6.
• The coolant pH
increased to ~ 9.0
• Yes!
Coolant pH
was “more stable and
capable” with NuSol
177M vs. competitive
material (C pk 0.80 vs.
0.44)

% TRAMP OIL IN THE COOLANT
CHANGED DURING THE TRIAL
• The chart shows a
decease in % tramp oil.
• Simultaneously the %
177M increased.
• The total oil remained
constant until a plant
addition.
• Anecdotally, the same
phenomena occurs with
the competition material
(increased % cupper =
decreased % tramp).

DID NUSOL 177M DESTABILIZE
THE % TRAMP OIL?
• Chemtool Crystal Lake
lab analysis showed the
% of gear oil and cupper
lube were constant.
• The in-use test method
gave inaccurate results.
• NO! % Tramp oil
was not destabilized by
NuSol 177M!
• A more accurate test
method was developed &
rolled out to the
customer.
NuSol 177-M
1.0
0.5
0.0
% NuSol 177-M in Oil Split (BRIX)
NuSol 177-M = 5.26558 - 0.0652284 Brix
S = 0.0120906 R-Sq = 99.9 % R-Sq(adj) = 99.9 %
65 70 75 80
Brix

DID NUSOL 177M IMPACT CUP
LUBE WEIGHT CONSISTENCY?
Cupper One Comparison
Lube
177M
X
Mean
15.631
13.714
S.D.
3.488
4.261
Min.
6
-12
Cupper Two Comparison
Lube
177M
X
Mean
16.167
15
S.D.
2.924
3.383
Min.
8
8
Max.
26
20
Max.
27
27
Range
20
32
Range
19
19
• No! Cup Lube
weights were MORE
consistent during the
trial (lower S.D.), but
the competitor
inconsistency was
likelydue to mechanical
issues identified bt
Chemtool.
• Defective solenoids on
both application units.
(Replaced).
• Lube supply not
touching bottom of coil
on cupper one
(Repaired).

WHAT IMPACT TOP WALL CONCENTRICITY
DID NUSOL 177M HAVE?
CONCENTRICITY DATA SUMMARY
Variable
Mean
TrMean
StDev
Minimum
Maximum
Range
Other
0.006046
0.006045
0.000111
0.0056
0.00646
0.00086
177M
0.006053
0.006053
0.000109
0.00567
0.00644
0.00077
None! The
concentricity results are
“Statistically Similar.”

CUP MAT CONVEYOR ISSUES
• DATA IMPUT
• Unusually, the cupper conveyor system with more
mechanical issues had fewer tear-offs
• Six Sigma correlation made with “line stops” and
tear-off rates (p-value)
• SIX SIGMA CORRELATION INVESTGATION
• CUP conveyor run on line stops
• Cups are rubbed “dry”
• Cups are dumped after one (1) hour stops
• Explanation of why the cupper with less line stops
has lower tear-off rates (lube loss)
• PROPOSED CORRECTIVE ACTION
• Cup conveyor “auto-stop” with line back-up (No lube
loss)

CONCLUSIONS
• ADDITIONAL ISSUES IDENTIFIED
• Metal trial
• Cup Conveyor
• Cup lube application failure
• SIX SIGMA DATA ANSWERS
• Improved or equal performance in cup lube
weights, coolant pH, % coolant tramp oil,
and top wall concentricity!
• Statistically Significant 12.5%
IMPROVEMENT in Tear-off rate in spite
of mechanical and metal issues!

QUOTATIONS
• “The goal is to transform data
into information, and information
into insight.” Carly Fiona
• “As Luce reminded me, he said,
without data, , without facts, the
discussion….is just another
opinion.”
• “When you cannot measure,
when you cannot express in
numbers, your knowledge is of a
meager and unsatisfactory kind:
(Lord Kelvin)