First, subject selection

PPR aluminum plastic tube is composed of 5 layers, the middle layer is made of aluminum sheet. The forming process is more complex, and there are differences with other pipes, no sizing sleeve, vacuum water tank. So the welding quality of aluminum strip is the key factor of pipe forming. It is found that there are still major defects in the 5 processes, which affect the production stability and lead to the low indicators of PPR aluminum-plastic pipe.

After summarizing and analyzing customer complaints in 2021, the workshop learned that PPR aluminum-plastic pipe accounted for 57.14% of the total complaint rate of the workshop.

In addition, the defective product rate in the first half of 2022 is as high as 8.34%, which is a great quality hazard and cost waste. Therefore, this project is selected for improvement.

Second, reason analysis

The fishbone diagram is used for specific analysis:

Based on the end factors obtained by the team members through analysis, the cause confirmation schedule was formulated:

Confirm that the key factors are distributed in three aspects: personnel factor, equipment factor and material factor, and implement countermeasures after updating the target value:

Third, the implementation of countermeasures

Solve the problem of insufficient capacity of operators (personnel factors)

Solve the problem of insufficient debugging capacity (personnel factor)

Installation of automatic detection device for pipe anomalies (equipment factor)

Standardized control of aluminum strip storage mode and storage cycle (equipment factor)

Remaking the forming wheel platform (equipment factor)

External mold channel improvement (equipment factor)

Solve the penetration phenomenon of external plastic co-extrusion line (equipment factor)

Standard maintenance control for aluminum belt molding parts (equipment factors)

Solve the phenomenon of unqualified performance index of aluminum brought into the factory (material factor)

Solve the hot melt adhesive effect of poor phenomenon (material factor)

Solve the inner glue leakage phenomenon (material factor)

Four, check the effec

In order to check the achievements of the research team, the data from January to June in 2009 were compared with the data from July to September in 2009:

All the objectives of the project have been achieved. In order to consolidate the achievements of the project, the following measures are formulated:

Five. Summary of achievements

Through the joint efforts of the workshop team and the research institute, the old problem of complaint rate and defective rate of PPR aluminum-plastic pipe has been completely solved. The follow-up workshop will continue to take effective strengthening measures to ensure that the indicators of PPR aluminum-plastic pipe continue to decline after the improvement, and no longer rebound:

1. Keep an eye on the indicators of PPR aluminum-plastic tubes and make them public every day;

2. The startup ability of the debugger is continuously improved and expanded;

3, the molding parts according to the standard maintenance work, and output records.