1. - Priorities
1.1. - Project charter for overall goal
1.2. - Short Term
1.2.1. - Jay - Welder Staffing - Tucson Mgmt (Jay, Mike, Mark)
1.2.2. - Morris - Solve P&A Issues - TAS Fab, Process Technology, R&D
1.2.3. - Jay - Melting Optimization - TAS Fab, Process Technology, R&D
1.2.4. - Josh - Annealing & Rolling - TAS Fab, Process Technology, R&D
1.2.5. - Garrett - Cooling Tubes (OPS, Process Technology)
1.3. - Medium Term
1.3.1. - Jay - Metal Amount in TAS (Beth, TAS Mgmt, Capital)
1.3.2. - Alex - Leg & Bushing Models - (R&D
1.3.3. - Garrett - Cooling Tube
1.3.3.1. - possible redesign
1.3.4. - Alex - D48-300 (Etowah)
1.3.5. - Josh - Quality Program (TAS, Process Technology, Pat Reinagle)
2. - Goal 1
2.1. - Consistently produce 6 high quality transverse row DDCS bushings per week by July 1st, 2015
2.2. - Strategies
2.2.1. - Design
2.2.1.1. - Tip Design
2.2.1.1.1. - Tapered / Extreme Tapered Tips
2.2.1.2. - Tip Plate Thickness
2.2.1.3. - Optimization of Cooling Tube Adjustment & Reducing/Eliminating Leaks
2.2.1.3.1. - Material Change
2.2.1.3.2. - Weld seam design change
2.2.1.3.3. -
2.2.1.4. - 10u future tip plate problems with production
2.2.1.5. - Modeling
2.2.1.5.1. - Boundary Conditions
2.2.1.5.2. - Design Criteria
2.2.1.5.3. - Improve cycletime and workflow
2.2.2. - TAS Fabrication
2.2.2.1. - P&A Issues
2.2.2.1.1. "D41 only for now"
2.2.2.1.2. - Small bore size takes a long time
2.2.2.1.3. - P&A Future Replacement
2.2.2.2. - Support Wires
2.2.2.3. - Cooling Tube Production Lead-time
2.2.2.4. - Welding
2.2.2.4.1. - Corners
2.2.2.5. - Efficiency Gains
2.2.2.5.1. - Reduce Scrap Rates (All stages)
2.2.2.6. - Quality
2.2.2.6.1. - Documentation / SOPs
2.2.2.6.2. - In-Process Quality Metrics / Checks (review)
2.2.2.6.3. - Material Quality
2.2.2.6.4. - Dye Penetrant Inspection
2.2.2.7. - Labor Issues
2.2.2.7.1. - Diminishing Skill sets
2.2.2.7.2. - Quality Workmanship
2.2.2.7.3. - Morale
2.2.2.7.4. - Staffing
2.2.2.7.5. - Welder Training
2.2.2.8. - Automation
2.2.2.9. - Melting
2.2.2.9.1. - Rollover Improvement
2.2.2.10. - Scheduling Improvements
2.2.2.10.1. - Minimize scrap
2.2.2.10.2. - Minimize changeovers
2.2.2.11. - Root Cause / Failure Analysis
2.2.2.11.1. - From Ops
2.2.2.11.2. - From TAS
2.2.3. - OPS
2.2.3.1. - Cooling Tube Adjustment Problems
2.2.3.1.1. - Better tools for adjustment
2.2.3.1.2. - Anti-Seize Improvement
2.2.3.1.3. - Modified bolt adjustment methods
2.2.3.2. - Best Practices
2.2.3.2.1. - Bushing Adjustments
2.2.3.2.2. - Maintenance
2.2.3.3. - Bushing Specialist at each plant
2.2.3.3.1. - Makes all bushing adjustment
2.2.3.3.2. - Single point of contact
2.2.3.4. - Feedback on performance to COE / TAS
2.2.3.5. - Transverse Row Training
2.2.3.5.1. - Practicing on models
2.2.3.5.2. - Other training
2.2.4. - Special Cause Variation
2.2.4.1. - Power Outage
2.2.4.2. - Cooling Air/Water Interruptions
2.2.4.3. - End Block Changes
2.3. - Contingency Plans
2.3.1. - Milestones
3. - Goal 2
3.1. - Communications between the Bushing COE and Outside Groups
3.1.1. - Monthly COE Calls
3.1.1.1. - Ops Teams
3.1.1.2. - TAS
3.1.1.2.1. - Attendees
3.1.1.2.2. - To-Do
3.1.1.3. - EU
3.1.1.4. - Internal COE Only
3.1.1.5. - Exception Reporting
3.1.2. - Business Leader Report Out
4. - Bushing Reliability
4.1. - TAS Quality Control
4.2. - Design
4.2.1. - Understanding Boundary Conditions
4.2.2. - Special Cause Variation
4.3. - Obstacles/Strategy
4.3.1. - Understanding of quality
4.3.1.1. - metrics
4.3.1.2. - objectives
4.3.1.3. - timing
4.3.1.4. - Tools/space
4.3.2. - Cooling Tube / Manifold Issues
4.3.3. - Skilled Labor Force Available
4.3.3.1. - Bored, lack of variation, want something new
4.3.4. - Material Properties
4.3.5. - Root Cause / Failure Analysis
4.3.6. - Document / Quality SOPs
5. - Bushing Performance
5.1. - Ops Team Training
5.2. - Design
5.3. - Obstacles/Strategy
5.3.1. - Special Cause Variation
5.3.2. - Cooling Tube Issues
5.3.3. - Operations Acceptability
5.3.4. - Root Cause Failure Identification
5.3.5. - Best Practices for Installed Bushing Maintenance
5.3.6. - Best Practice for Tuning the Bushing to the Glass
5.3.7. - Operations Specialist for Bushing Adjustments
6. - Feedback Loops
6.1. - Cut-Up > Melting
6.2. - TAS > Set-Up > Production > Design
6.3. - Design > Modeling > TAS Fab
7. - TAS Process Flow
7.1. - Kolene
7.2. - Tear Down
7.3. - Cut-Up
7.4. - Melting
7.5. - Rolling
7.6. - Annealing
7.7. - Parts
7.8. - Welding
7.9. - Mounting
7.10. - Macro Flow
7.10.1. - Design
7.10.2. - TAS
7.10.3. - Set-Up
7.10.4. - Production
7.10.5. - Life-Out