Reduce Defects by Controlling the Spraying Process via Images Compare and Revamping Lean Six Sigma Toolbox

Abstract

Ideal-Standard factory suffers from disturbance in covering them Bathtubs by chemical liquid, which must cover all surfaces the same thickness. The main reason for that suffering is the emergence of bubbles in the liquid via vortex phenomenon (i.e., waste) that cause a defect in spraying process. This phenomenon is one of the hydrodynamic instability that pushes the liquid in the hoses with different pressures, then unbalance covers' layer of spraying liquid on a Bathtubs and reduce its resists against heating circumstances. The Vortex flow is subject to a number of major structural changes involving very large disturbances when a characteristic ratio of catalyst to axial velocity components is varied. Therefore, this paper proposed a VSCM algorithm (vortex stream control map) that discusses via DMIAC roadmap through two phases. The first describes and detect the waste by imaging and monitoring the vortex and comparing them with standard saving in local database. The second use the Genetic code to select the best camera position and manipulating the database that used in decision making through control step to cessation spraying process if the bubbles move out of its allowable range.