BeltBlack学习教案

1、会计学1BeltBlack第一页，共19页。Business Reason:Warranty Cost Reduction Initiative: Customer FocusedUnparalleled Customer ExperienceProject SponsorsBill Bain, Power Development, Chartering ManagerScott Wise, Global BPI, Black Belt BPI MentorBeth Chase, PG BPI Business ChampionProject TeamAlan Becklein, Qualit

2、y, Team LeadRobert Allen, AC adapter Eng.Sam Stimson, SEQJeffery Wei, Liteon GQAMKwebena Asante, AC adapter Eng.Anil Kurugode, AC adapter DMJonathan Wan, FinanceBenchmarked Projects:No adapter projects found in the tracking toolReviewed several quality improvement projects completed on C-series adap

3、tersWhat was Learned about AC adapters:DC cable impact on overall AC adapter warranty costLessons learned from C-series not fully applied to D-seriesLoose interaction between mechanical and power developmentIncomplete qualification of DC cable no specification, or test requirement coverage for commo

4、n customer usage environmentsPoor qualification and monitoringLimited failure analysis review, incoming inspectionCross-functional TeamStakeholders第1页/共19页第二页，共19页。CustomersOutputsProcessInputsSuppliersPortable system usersAC adapterInitial adapter qualificationmanufacturing process capabilityMechan

5、ical & Electrical SpecificationsAC Adapter TeamAC Adapter TeamTest resultsprototypesAdapter developmentDell RFQUsage environmentCompetitive knowledge Portable SystemRequirementsCOPISHigh Level Process MapClear Process Definition ConsensusFocusPortable Power RequirementsAdapter SpecificationsCustomer

6、 UsageMass Production Capability第2页/共19页第三页，共19页。CustomersNeedsPossible CTQs (Metric)Specification DC cable ManufacturingCustomersSuppliersSystem TeamHardwareTestMfg. DiagnosticsPost-RTS IndicatorsStop-shipsIFIRFIRGeneration Trend (C vs D series)Class Trend (65W, 90W, 130W, etc.)Failure Analysis par

7、etosProduction StatisticsFPYCable incoming inspectionsDC cable process capabilityGeneration Trend (C vs D series)Class Trend (65W, 90W, 130W, etc.)DriversqUsage EnvironmentqMaintain FeaturesqMaintain ID qImprove QualityqMaintain CostReliabilityUsed brainstorming and CTR Tree to define family of meas

8、ures.第3页/共19页第四页，共19页。Inspiron IFIRInspiron 90 Day FIRCustomerHolds/Stop-shipsElimination of PSID Failures3Baseline3347 DPPM1.09%900 DPPM 1138 DPPM306 DPPM0.30% 669 DPPM 180 DPPMZeroGoal2677 DPPM0.80%720 DPPM0.24%0 DPPM0 DPPM0 DPPM0 DPPMPFQTFQQQQQQPFQT Productivity, Qualitative, Financial, Time$488,

9、000 Estimate SavingsElimination of DC cable Damage FailuresLatitude IFIRLatitude 90 Day FIR第4页/共19页第五页，共19页。Verified Data NormalityProb 0.05FYxx FIR.01.05.10.25.50.75.90.95.99-3-2-10123Normal Quantile Plot.0005 .0006 .0007 .0008 .0009 .001MeanStd DevStd Err Meanupper 95% Meanlower 95% MeanN0.0006954

10、0.00010720.00001110.00071740.0006735 94MomentsLocationDispersionTypeMuSigmaParameter0.00069540.0001072Estimate0.00067350.0000937Lower 95%0.00071740.0001251Upper 95%Parameter Estimates Shapiro-Wilk W Test 0.978080W 0.4492ProbWGoodness-of-Fit TestFitted NormalIncreasedVariabilityVariation第5页/共19页第六页，共

11、19页。Key Root Cause Listing:Design weakness related to PSID EEPROMLimited Mechanical development engagementDC cable requirements not completeDC cable test requirements guidelines not complete.Contributing Factors AnalysisDefect Pareto AnalysisContributing Factors AnalysisBrainstormingFMEAMechanical A

12、ssessmentIncompleteDevelopmentProcesses第6页/共19页第七页，共19页。Actions: FY05Design PSID protection circuitDC cable process capability oversight (sign-off, audits)DC cable environmental design strategyAC adapter design specification updated (xxx-xxx)Development Guidelines / Development ChecklistDevelopment

13、of sub-tier cable supplier process capabilityFailure analysis metrics policyGet-Well Projects based on Defect Pareto AnalysisDevelopment of DC cable test casesDC cable Definition Team (Engineering, Quality, Mechanical, Reliability, Marketing)“Just Do It”GuidelinesSupplierInitiatives第7页/共19页第八页，共19页。

14、 Deployment: Initiated June FY05Deployment Timeline:All 65W adapter suppliers shipping by June 18thAll 90W adapter suppliers shipping by July 2ndRemaining adapter suppliers shipping by July 23rdIFIR Results第8页/共19页第九页，共19页。Inspiron IFIRInspiron 90 Day FIRCustomerHolds/Stop-shipsElimination of PSID F

15、ailures3Baseline3347 DPPM1.09%900 DPPM1138 DPPM306 DPPM0.30%669 DPPM 180 DPPMZeroGoal2677 DPPM0.80%720 DPPM0.24%0 DPPM0 DPPM0 DPPM0 DPPMActualN/A2420 DPPM0.53%673 DPPM0.17%Elimination of DC cable FailuresLatitude IFIRLatitude 90 Day FIR$1,440,000 Annualized Savings211 DPPM79 DPPMN/AN/A第9页/共19页第十页，共1

16、9页。Reduced VariabilityIFIR第10页/共19页第十一页，共19页。How Standardized:Communication of Best Practices:Next Steps: “Complete DC cable DOE”AC adapter design specification (xxx-xxx)Development of DC cable test casesDC cable process capability oversight (sign-off, audits) DC cable Definition Team (Engineering,

17、Quality, Mechanical, Reliability, Marketing)PG Quality, Engineering, WWP Supplier Engineering & QualityUsage of Statistical methods on IFIR and FIR MetricsSeveral improvement recommendations with no customer dataDeploy improvement combinations under the control of a DOEAnalyze results and select the

18、 best combination of improvements SustainedResults!第11页/共19页第十二页，共19页。 Guidelines, specificationsand training are available!第12页/共19页第十三页，共19页。第13页/共19页第十四页，共19页。GoalFY03 0.06%FY04 0.11%Foxconn MBconnector issueLiteon 130Winductor issueAcoustics motherboardpower circuits and manufacturingProcesses a

19、ddressedBaseline measured第14页/共19页第十五页，共19页。Refer to the PSID Total saving as of Sept04 for calculation details.第15页/共19页第十六页，共19页。 Actions:ItemRPNRecommended ActionsOwnerCompletePSID protection circuit development630Platform Development GuidelinesIncluding qualificationR. AllenQ2FY05Mechanical & Re

20、liability reviews inconsistent340Mechanical & Reliability Review Initiative; update guidelines.A. KurugodeD. HernandezQ4FY05Feature implementation inconsistent325Treat power commodities as a Tier 1 commodity.PG Mgmt. TeamQ3FY05Power core team lacking resources290Development Guidelines incomplete250Update Development GuidelinesR. AllenK.