8D WELDING TEAM PROCESS ACTIONS(11/4/09

D3. Interim Actions:
1. Refresher training for operators was accomplished. Action item for Scott: find date this was accomplished and list of people trained. 1/30/09, by My. Is there a list of people who were trained on that date? Complete: Yes, it is in the HR Training Log.

2. The work instruction W-7.5-60 Microwave Assembly Instructions includes the steps for applying the epoxy. It has a torque specification for the screws that attach the midplate to the horn, but this may be outdated. It was last updated 10/20/08. Action item for Phil: update the WI with correct torque spec and the name of the epoxy used in the assembly process. W-7.5-60 updated with torque spec set to "4". Is that 4 lb-in? Has training to this work instruction update been accomplished? Complete: Torque spec should be 6 in-lbs. Torque drivers are calibrated and a sticker is place over the torque setting on the drivers. Action item: Chip to ensure training to the torque spec and to post a sign that these torque drivers cannot be used anywhere else in Production.

3. The work schedule and task rotation for microwave assembly needs to be understood and actively managed to maintain the quality of the epoxy application. Action item for Chip: determine what this schedule is and recommend any changes needed to avoid operator fatigue. Approximately 15 minutes out of every two hours in microwave assembly requires applying epoxy, which should not cause fatigue. The number of assemblies accomplished consecutively taken together may cause fatigue, however. What is the optimum number of assemblies that an operator should accomplish before rotating out of this task? Not complete. Action item for Chip, per Scott: Get feedback from Kaizen event in the first week of December to determine the optimum number of assemblies before rotating an operator out of the task.

4. The molded keep-out should be delivered soon. Action item for Phil: ensure delivery. Complete. The keep-out has been in use since 10/19/09.

5. The procedure for cleaning cured epoxy from the edge of the microwave chamber needs to be standardized. Strongly consider banning the use of steel wool. Action item for Alec: identify the relevant work instruction and recommend an update. Complete: W-7.5-13 updated to permit only the use of cotton swabs and alcohol to clean epoxy off the microwave assembly.

6. Action item for Alec and Kexa: update W-7.5-60 to include the use of the keep-out. Not complete: To date, three operators have used the keep-out. We need feedback from them and two more operators to determine best practices for an update to the work instruction. Action item for Chip: add two more operators to the rotation; get feedback from all five. Update to work instruction needs to include cleaning and inspecting the keep-out for damage.

7. Action item for Paul Harrison: look up CSD work instruction and make sure the epoxy cleaning instruction is the same as for Production. Complete: CSD troubleshoots down to the board level, but not component, so they do not clean epoxy from the microwave assembly.

8. Action item for Andy: ensure W-7.5-13 is being used in Test. Complete: Test uses W-7.5-24, but not W-7.5-13.

9. Action item for Scott: ensure all steel wool is removed from the Production area. Complete.

D5. Permanent Corrective Actions to be evaluated (Kexa):
10. Application of epoxy by mini-stencil: consider the characteristics of the current Ablebond 84-1LMI NB (cure time, manufacturer’s recommended use, shelf life); required film thickness vs. capability of stencil; necessity of some kind of alignment fixture for the stencil. Status of developing CAD data for the mini-stencil? No update. Richard Hinsley has had other priorities. Update next meeting.

11. A preformed gasket made of a conductive, compressive film. We need a true gasket for this proposed corrective action, and not a pre-formed epoxy. Have you found a material and a supplier? Do we understand the requirements of this material? No update. Kexa has not been able to find a material that meets our requirements. Update next meeting.