DMAIC应用案例

1、Form #: 00-LS80-F103-A Revision Date: Apr. 1st, 2012FPY&UPH Improvement FPY&UPH Improvement for Hellofor HelloPreparedPrepared by: Stone Fuby: Stone FuUpdated: Apr30Updated: Apr30thth, 2015, 20151Form #: 00-LS80-F103-A Revision Date: Apr. 1st, 20122Team IntroductionProject leader: Stone FuPr

2、oject champion: Jeremy ChungLean Member: Shanshan YaoCore team members: ME: Jack Lee, William Pan; MFG: Jackie Jiang, HS Chen; TE: Dave Huang, Dijin Li; QE: Wenming Liu, Stone Fu, Milo Huang; IE: HuaDong Liang; Planner: Ada Song; IA: Kitty He; Buyer: Eva Xie WCM: Kite PanForm #: 00-LS80-F103-A Revis

3、ion Date: Apr. 1st, 20123 Currently FPY range is 70.0%-76.6%, it is very low and not very stable. Improve average FPY from 72.4% to 90.0% at least. Challenge goal is 95%.Opportunity StatemenmentGoal Statement Goal Statement Project ScopeFPY Improvement RateDMAIC Hello project Bay51Form #: 00-LS80-F1

4、03-A Revision Date: Apr. 1st, 20124DMAICForm #: 00-LS80-F103-A Revision Date: Apr. 1st, 20125DMAICCurrent FPY trendAverage FPY from (wk10 to wk15) is 72.4%,Average FPY from (wk10 to wk15) is 72.4%,it is greatly lower than goal .it is greatly lower than goal .Form #: 00-LS80-F103-A Revision Date: Apr

5、. 1st, 20126Goal set upDMAICForm #: 00-LS80-F103-A Revision Date: Apr. 1st, 20127DMAICTopTop5=5=8585%Form #: 00-LS80-F103-A Revision Date: Apr. 1st, 20128Lack of trainingUSB cannot insert well by operatorHumidity of UUT cant match humidity of test chamber quickly.Defect as incomingNon-buy offFW is n

6、ot updatedDMAIC Working T&H is not matched with the UUTRelax the test rangeHumid FailedForm #: 00-LS80-F103-A Revision Date: Apr. 1st, 2012DMAIC9Lack of training Work place T&H is not suitable for workingNo wearing anti-static gloves/finger cotNew comersPart scratch as incomingThe assembly f

7、ixture surface is hard, easliy have damage to part rubbing the part on the working tablelong fingernails Part piled up in line or in trayScratchScratchForm #: 00-LS80-F103-A Revision Date: Apr. 1st, 2012DMAIC10Assembly processwrong orientation, missingSpeaker dimention is not matched with its chambe

8、r Workshop T&H is not suitable for speaker assemblyNew tester, non buy-offNew comer, lack of training, experienceTester method need improvedSpeaker assembly is not matched with the unit after assembledAssembly process need improvedBridge happened in soldering processSpeaker Speaker FailedFailedF

9、orm #: 00-LS80-F103-A Revision Date: Apr. 1st, 2012DMAIC11Lack of experience operator wrong operationWorkshop Is not dust-freeTest firmware changedDust sensor cable/air dust defective as incomingTest chamber is not cleanThe Frequency of cleaning the workshop floor is not enoughDustDustForm #: 00-LS8

10、0-F103-A Revision Date: Apr. 1st, 2012DMAIC12New comer, lack of experience Workshop T&H is not suitable for workingCenter assembly part is not assemblied in placeAssembly process need improvedCenter insert assembly surface is not flat as incomingAssembly fixture is not fixed wellGapGapForm #: 00

11、-LS80-F103-A Revision Date: Apr. 1st, 201213DMAICForm #: 00-LS80-F103-A Revision Date: Apr. 1st, 2012Open item1. OEE-PlantFailed ItemFailed ItemCurrent ActionFailed Rate Chart Before & After ActionLong-term ActionLong-term ActionHumid_Test failed at system level test.Suggest customer change the

12、Humid_Test tolerance from 5% to 10%; Suggest customer update test FW.DMAICAdded one fan to Added one fan to improve airiness in improve airiness in chamber to have chamber to have both UUT and test both UUT and test chamber humidity chamber humidity matched quickly.matched quickly.Cut in WK16Form #:

13、 00-LS80-F103-A Revision Date: Apr. 1st, 2012Open item1. OEE-PlantFailed ItemFailed ItemCurrent ActionCurrent ActionFailed Rate Chart Before & After ActionLong-term Long-term ActionActionScratch found at FNI stationTranquil propose to cancel sand blasting process but change to molding texture pr

14、ocess.DMAICCut in WK161: Changed the fixture material to soft one; 2: Align with customer for limit sample, and added source inspection station in line.Form #: 00-LS80-F103-A Revision Date: Apr. 1st, 2012Open item1. OEE-PlantFailed ItemFailed ItemCurrent ActionCurrent ActionFailed Rate Chart Before

15、& After ActionLong-term ActionLong-term ActionSpeaker OCT Get failed at system level test.Sending samples to customer(Hello) for further study.DMAICCut in WK171: Adding one Poka-Yoka fixture for speaker assembly;2: Optmizing AVI precedure to avoid failure flow next station;Form #: 00-LS80-F103-A

16、 Revision Date: Apr. 1st, 2012Open item1. OEE-PlantFailed ItemFailed ItemCurrent ActionCurrent ActionFailed Rate Chart Before & After ActionLong-term ActionLong-term ActionDust_Sensor failed at system level test.DMAIC1: Changed the firmware to the old version;2: Added one filter in the tester ch

17、amber.Performed old FW and added filter Suggest to build clean room with constant temperature and humidity for assembly and testing.Adding filter in tester chamber to reduce dust failed rateForm #: 00-LS80-F103-A Revision Date: Apr. 1st, 2012Open item1. OEE-PlantFailed ItemFailed ItemCurrent ActionC

18、urrent ActionFailed Rate Chart Before & After ActionLong-term Long-term ActionActionGap between external cosmetic shells and bottom cap failed at FNI station is caused by inner insert assembly part.NADMAIC1: Tranquil adjust the molding conditions, the holding pressure changed from 23 kg/m2 to 19

19、kg/m2 on Apr15.2: Added one fixture at IQC to check gap to avoid this failure flowed into line.Cut in WK16FixtureGap checked in advanceForm #: 00-LS80-F103-A Revision Date: Apr. 1st, 201219DMAICFPY Trend Chart Before & After ActionsNote: After actions taken the FPY trend towards up and reach goa

20、l 90.0% in WK17, and the FPY is stable.BeforeAfterForm #: 00-LS80-F103-A Revision Date: Apr. 1st, 201220DMAICAfter actions, our performance by station is:After actions, our performance by station is:Yield Set upYield After ActionsFrom above table, we reached goal setting at beginning at PCBA FVT and

21、 unit FNI stations, for FNI, also reached our challenge goal, but failed at unit FVT station, which need try our best to improve it in the following days.Form #: 00-LS80-F103-A Revision Date: Apr. 1st, 201221DMAICAfter actions, our failures down by day is:After actions, our failures down by day is:D

22、irect Financial Benefits:Direct Financial Benefits: Under assumption of PCBA scrap rate is 5%, every PCBA cost is $10, every labor cost is $2/H, 60pcs boards repair need 1 worker cost 1 hour, 10pcs units rework need 1 worker cost I hour. Failures down, total save cost by day is: 192*0.05*10+192/60*2

23、+(120+147)/10*2 = $155.8/day. Form #: 00-LS80-F103-A Revision Date: Apr. 1st, 201222DMAICPre-form VA have been released and controlled in DCC.New New PokaPoka- -yoke fixtureyoke fixtureForm #: 00-LS80-F103-A Revision Date: Apr. 1st, 201223DMAICPre-form VA have been released and controlled in DCC.New shell New shell assembly assembly fixturefixtureForm #: 00-LS80-F103-A Revision Date: Apr. 1st, 201224DMAICPre-form VA have been released and controlled in DCC.Form #: 00-LS80-F103-A