theyieldofGrindBeadproductsGB六西格码项目

theyieldofGrindBeadproducts-GB(六西格码项目2024/3/26theyieldofGrindBeadproductsGB(六西格码项目ProjectSummaryProjectTitle

IncreasetheyieldofGrindBeadproducts-GBProjectScope GrindBeadGreenBelt ******DeploymentChampion ******ProcessOwner ******FinanceRepresentative ******Mentor ******theyieldofGrindBeadproductsGB(六西格码项目ProjectTeamMembersTeamMembers&DepartmentsLeader:******ProcessEngineerMember:******ProcessEngineer

******ProductionSupervisor

******ProductionSupervisor

******ProductionSupervisor

******QASupervisor…theyieldofGrindBeadproductsGB(六西格码项目ProblemStatementProblemStatementTheyieldofGrindBeadproductsis77.53%fromJan-2010toMay-2010,whichimpactedFGTSseriouslyProjectObjectiveIncreasetheyield:From77.53%to90%bytheendofSep.2010BusinessBenefitsProjectedAnnualSavingsof$30KMeetCustomerDeliverytheyieldofGrindBeadproductsGB(六西格码项目ProjectBackgroundComment:GrindBeadYieldismorelowerthantheotherproducts.theyieldofGrindBeadproductsGB(六西格码项目ProjectBackgroundComment:1.GrindBeadbelongtoS100products.2.ThetotalyieldofS100iscloseto90%.theyieldofGrindBeadproductsGB(六西格码项目ProjectMetrics12.5%roomofimprovementBaseline=77.5%Target=90%theyieldofGrindBeadproductsGB(六西格码项目ProjectTimeFrame(Milestone)Define2010.06.01Measure2010.07.01Analyze2010.07.30Improve2010.08.20Control2010.09.01theyieldofGrindBeadproductsGB(六西格码项目FinancialImpact&SavingAssessedsaving=StandardCost*Forecast*(BaselineScraprate-TargetScrapRate)=USD30KActualSavingFromOctToDec:ActualSaving=USD59.4K

theyieldofGrindBeadproductsGB(六西格码项目Summary–Deliverables&ConclusionGrindBeadYieldwas77.5%fromJantoMay-2010,thereisabout12.5%potentialdefectratioreductiontoachievetarget90%bytheendof2010.ProjectedAnnualSavingsof$30KMeetCustomerDeliverytheyieldofGrindBeadproductsGB(六西格码项目IncreasetheyieldofGrindBeadproducts-GBLairdTechnologiesSixSigmaGBProject

MeasurePhasetheyieldofGrindBeadproductsGB(六西格码项目ParetoChartComment:1.ScrapdataisfromproductdailyreportinMay-20102.IntheParetoChartofDefectItem,Loss,chipandsamllIDoccupy99.0%oftotalscrapqty.Sotheyshouldbemainimproved.MainimprovedefectstheyieldofGrindBeadproductsGB(六西格码项目ParetoChartanalysisComment:Losscomefromthemanagement,Itmeanstheproductsdropawayduringthetransferring.Wehadarrangedameetingwithproduction.Pleaseseethebelowmeetingsummary.Afterproductionimproved,theParetoChartshowthemaindefectsareSmallIDandChips.关于少数的a.成型称对批量数量叶华飞韩应明(负责培训)2010-8-25b.各工序培训员工注意搬运手势避免掉落损坏产品S100所有班组长(负责培训)2010-8-25theyieldofGrindBeadproductsGB(六西格码项目ParetoChart-Sep.2010Comment:1.ScrapdataisfromproductdailyreportinMay-20102.IntheParetoChartofDefectItem,chip,samllIDandLossoccupy99.0%oftotalscrapqty.Sotheyshouldbemainimproved.MainimprovedefectsSmallIDChipLosstheyieldofGrindBeadproductsGB(六西格码项目ProcessMaptheyieldofGrindBeadproductsGB(六西格码项目IdentifyKPIVsManmaterialMethodEnvironmentLustrationDryness5SCostumeTechnicianskillGaugeInspectioncriteriaInspectionmethodWI(x)Operatorsskill(x)MachineMeasureKilnGrindingmachinePressingmachineSpeedDiamondwheel(x)CleaningStainlesstrayPressmachineLCRmeterProfileprojectorSamplesPO2PackageBoxesSelfcontrolConsciousnessSmallIDWItraining(x)SpeedPlasticbagsWorkstandardCleaningroomAirconditionPowderLotnoPowdersizeAdaptthemachine

PressconditionFiringprofile

PowderpropertiesWashingproceduretheyieldofGrindBeadproductsGB(六西格码项目IdentifyKPIVsManmaterialMethodEnvironmentLustrationDryness5SCostumeTechnicianskillGaugeInspectioncriteriaInspectionmethodWI(x)Operatorsskill(x)MachineMeasureKilnGrindingmachinePressingmachineSpeedDiamondwheel(x)CleaningStainlesstrayPressmachineLCRmeterProfileprojectorSamplesPO2PackageBoxesSelfcontrolConsciousnessChipWItraining(x)SpeedPlasticbagsWashingprocedureWorkstandardCleaningroomAirconditionPowderLotnoPowdersizeAdaptthemachinePressconditionFiringprofilePowderpropertiestheyieldofGrindBeadproductsGB(六西格码项目FMEAtheyieldofGrindBeadproductsGB(六西格码项目FMEAtheyieldofGrindBeadproductsGB(六西格码项目GageR&RSmallIDtheyieldofGrindBeadproductsGB(六西格码项目ControlChartControlChartIDdimensionComments:

InAugof2010,SmallIDactualscraprateis17.01%；Sigmalevel(ZValue)is0.013theyieldofGrindBeadproductsGB(六西格码项目PotentialKPIVsListAccordingtoanalysiswefoundfourpotentialKPIVs:1.Pressingprocess—Pressingcondition(SPI)2.Firingprocess—Temperaturesettings3.Grindingprocess—Washingprocedure4.Managementprocess—SourcingchaintheyieldofGrindBeadproductsGB(六西格码项目MeasurePhaseDeliverablesDevelopedtheParetoChartsDevelopedprocessmappingDevelopedFishboneDiagramandFMEAIdentifiedpotentialKPIVsDeliverables&ConclusionConclusionFromMeasurePhaseWehadconfirmedtheMeasuresystemGageR&RisOK.ThroughProcessmap,FishboneDiagram,C&EMatrix,FMEAanalysis,wefound4KPIVs.WehadmadetheActionPlanfor4KPIVs.theyieldofGrindBeadproductsGB(六西格码项目IncreasetheyieldofGrindBeadproducts-GBLairdTechnologiesSixSigmaGBProject

AnalysisPhasetheyieldofGrindBeadproductsGB(六西格码项目PotentialKPIVsIdentified–SummaryNoKPIVHypothesisTest1Pressingprocess—Pressingcondition(SPI)Twosamples2Firingprocess—TemperaturesettingsTwosamples3Grindingprocess—WashingprocedureNoneedtest4Managementprocess—SourcingchaintheyieldofGrindBeadproductsGB(六西格码项目KPIV1:

ChangetheKPIV1canimpacttheSmallIDscraprate.KPIV1DetailPressingprocess—Pressingcondition(SPI)

Before:Wesettheaveragevaluearound1.77afterfiringsamples.Changemethod:Wesettheaveragevaluearound1.79afterfiringsamples.Andsincethepinwillbedamagedafterperweek.Wewillcheckifthepressingconditionneedtobechangedweekly.HypothesisTestTwosamplestestwillbeusedtotestthisKPIV.HypothesisStatementHo:AfterchangeKPIV1,theIDdistributionisassameasbefore.Ha:AfterchangeKPIV1,theIDdistributionisnotsameasbefore.

theyieldofGrindBeadproductsGB(六西格码项目KPIV1:

ChangetheKPIV1canimpacttheSmallIDscraprate.HypothesisTest(SmallID)Comments:P-Value<0.005,theresultshows

afteradjustpressingcondition,SmallID(P(2))reducedobviouslyandsignificantly.P-Value<0,005theyieldofGrindBeadproductsGB(六西格码项目KPIV1:

ChangetheKPIV1canimpacttheSmallIDscraprate.HypothesisTest(SmallID)P-Value<0,005NonnormaltheyieldofGrindBeadproductsGB(六西格码项目KPIV1:

ChangetheKPIV1canimpacttheSmallIDscraprate.HypothesisTest(SmallID)Comments:P-Value<0.005,thedataisnonnormal,2sample-Ttestcanbeusedforit.P-Value<0,005NonnormaltheyieldofGrindBeadproductsGB(六西格码项目HypothesisTest(SmallID)Two-SampleT-TestandCI:S10T050917,S10TE050923Two-sampleTforS10T050917vsS10TE050923NMeanStDevSEMeanS10T050917501.77240.01330.0019S10TE050923501.779200.003400.00048Difference=mu(S10T050917)-mu(S10TE050923)Estimatefordifference:-0.00680095%CIfordifference:(-0.010662,-0.002938)T-Testofdifference=0.05(vsnot=):T-Value=-29.18P-Value=0.000DF=98BothusePooledStDev=0.0097P-Value=0,000P(1)≠P(2)Comments:P-Value=0.000,theresultshows

afteradjustpressingcondition,SmallID(P(2))reducedobviouslyandsignificantly.KPIV1:

ChangetheKPIV1canimpacttheSmallIDscraprate.Testingmean1=mean2(versusnot=)Calculatingpowerformean1=mean2+differenceAlpha=0.05Assumedstandarddeviation=0.0133SampleTargetDifferenceSizePowerActualPower0.01390.90.906249Thesamplesizeisforeachgroup.theyieldofGrindBeadproductsGB(六西格码项目KPIV2:

ChangetheKPIV2canimpacttheChipscraprate.KPIV2DetailFiringprocess—Top-temperature

Before:1220℃for24B0110-010Changemethod:1190℃for24B0110-010

HypothesisTestTwoSamplestestwillbeusedtotestthisKPIV.Weneedtosuretemperaturechangewillnotaffectthefinalproperties.HypothesisStatementHo:AfterchangeKPIV1,thepropertiesareassameasbefore.Ha:AfterchangeKPIV1,thepropertiesscrapratearenotsameasbefore.

theyieldofGrindBeadproductsGB(六西格码项目PowerandSampleSizeforRandΦ.

Testingmean1=mean2(versusnot=)Calculatingpowerformean1=mean2+differenceAlpha=0.05Assumedstandarddeviation=0.3857SampleTargetDifferenceSizePowerActualPower0.0515480.950.950062Thesamplesizeisforeachgroup.Weneed1548samplesdataforthiscontrastatleast.KPIV2:

ChangetheKPIV2canimpacttheChipscraprate.WechangedtheKPIV2onOct-2010.theyieldofGrindBeadproductsGB(六西格码项目HypothesisTest(Chip)P-Value=0,378P(1)=P(2)P-Value=0,883P(1)=P(2)Comments:P-Value>0.05,theresultshows

afterreducedthetoptemperature,Properties(RandΦ

)isstillsamewithbefore.Thepropertiesdidn’tchangesomuch.Two-sampleTfor1190-2vs1220NMeanStDevSEMean1190-22513.5160.3950.07912202513.4490.3860.077Difference=mu(1190-2)-mu(1220)Estimatefordifference:0.06640095%CIfordifference:(-0.155591,0.288391)T-Testofdifference=0.05(vsnot=):T-Value=0.15P-Value=0.883DF=48BothusePooledStDev=0.3904IndividualValuePlotof1190-2,1220Boxplotof1190-2,1220

KPIV2:

ChangetheKPIV1canimpacttheChipscraprate.Two-sampleTfor1190-1vs1220NMeanStDevSEMean1190-12513.4230.1890.03812202513.4490.3860.077Difference=mu(1190-1)-mu(1220)Estimatefordifference:-0.02640095%CIfordifference:(-0.199156,0.146356)T-Testofdifference=0.05(vsnot=):T-Value=-0.89P-Value=0.378DF=48BothusePooledStDev=0.3038IndividualValuePlotof1190-1,1220Boxplotof1190-1,1220

theyieldofGrindBeadproductsGB(六西格码项目HypothesisTest(Chip)P-Value=0,447P(1)=P(2)P-Value=0,261P(1)=P(2)Comments:P-Value>0.05,theresultshows

afterreducedthetoptemperature,Properties(RandΦ

)isstillsamewithbefore.Thepropertiesdidn’tchangesomuch.Two-sampleTfor1190-2vs1220NMeanStDevSEMean1190-25000046.8000.8070.165000046.501.060.2Difference=mu(1190-1)-mu(1220)Estimatefordifference:0.30400095%CIfordifference:(-0.233542,0.841542)T-Testofdifference=0(vsnot=):T-Value=1.14P-Value=0.261DF=44KPIV2:

ChangetheKPIV1canimpacttheChipscraprate.Two-sampleTfor1190-1vs1220NMeanStDevSEMean1190-15000046.6910.6890.145000046.501.060.21Difference=mu(1190-3)-mu(1220)Estimatefordifference:0.19565095%CIfordifference:(-0.318849,0.710149)T-Testofdifference=0(vsnot=):T-Value=0.77P-Value=0.447DF=41theyieldofGrindBeadproductsGB(六西格码项目Summary–ConclusionSignificantKPIVs

ThebelowpotentialKPIVshavebeenidentifiedassignificant;andfurtheractionwillbetakentoimplementtheimprovementplansinthenextphase:KPIV1:Reviewingthepressingconditionoftenly.KPIV2:Reducethetoptemperature.KPIV3:Changethewashingprocedure.KPIV4:Theoperatorwillcheckthequantitiesforeachbatchwhentheproductsbeshippedtonextprocess.theyieldofGrindBeadproductsGB(六西格码项目IncreasetheyieldofGrindBeadproducts-GBLairdTechnologiesSixSigmaGBProject

ImprovePhasetheyieldofGrindBeadproductsGB(六西格码项目Improvement&ActionPlanSummaryNoKPIVActionOwnerDueDateStatus1Pressingprocess—Pressingcondition(SPI)1.Checksamplesresultwhenanewsetoftoolingwillbeused.******8-OctClosed2.Checksamplesresultforeachmachineweekly.******8-Oct2Firingprocess—TemperaturesettingsReducedthetoptemperaturefrom1220℃to1190℃.******8-NovClosed3Grindingprocess—WashingprocedureImplementnewwashingprocedureaftergrinding.******1-DecClosed4Managementprocess—SourcingchainTheoperatorwillcheckthequantitiesforeachbatchwhentheproductsbeshippedtonextprocess.

******8-OctClosedtheyieldofGrindBeadproductsGB(六西格码项目Pressingprocess—Pressingcondition(SPI)

canimpacttheSmallIDscraprate.

KPIV1:WecheckedsomebatcheswithhighSmallIDscraprate,andwefoundonlypressingconditionwhichcanimpactSmallIDseriously,perteamanalysis,wefondthatthereleasingconditionistherootcause,andwechangedpressingconditionatthattime.From8thOct,wedidsometestwithdifferentpressingconditionbysamemachine,thetestresultisasbelow:BatchLot#PressingconditionSmallIDScrapRateMachineS10T0509170.225g/pc8.01%RP3#S10TE0509230.234g/pc1.03%RP3#Fromtheabovesheet,wecanfindthatused0.234g/pcreleasingagentthesmallIDscraprateisthelower.Sofrom8thoct,0.234g/pcpressingconditionwasusedbyallpressingprocess.theyieldofGrindBeadproductsGB(六西格码项目Pressingprocess—PressingconditioncanimpacttheSmallIDscraprate.

KPIV1:From8thto28thOct,wedidmanyteststooptimizethepressingcondition,andbaseonthetestdata,wedrewaconclusion:ThepressingconditionchangedthattheSmallIDscrapratewaschanged.Thetoolingwillbedamagedafter1or2weeksanditwillaffectthescrapratealso.Itmeansweneedtoadaptthepressingconditionoftenly.Lot#PressingconditionSmallIDScrapRateMachineS10T0509500.234g/pc3.40%RP3#S10T0509680.234g/pc7.40%RP3#S10T0509810.234g/pc9.50%RP3#theyieldofGrindBeadproductsGB(六西格码项目Firingprocess—Top

temperature

canimpacttheChipscraprate.

KPIV2:Wecomparedthechipscrapratefor35B0110-010and24B0110-010.Andwefoundthechipscomefrom24B0110-010mainly.Andthegrindingprocessforthesetwoitemsarebothsame.Sowethinkthematerialof24B0110-010istoomuchhardthan35#material.Sowedecidetotestlowerfiringtemperaturefrom28th-Sep.Whenthetemperatureischangedto1190℃,wefoundtheyieldincreasedafewpercents.theyieldofGrindBeadproductsGB(六西格码项目Grindingprocess—WashingprocedurecanimpacttheChipscraprate.

KPIV3:Aftergrinding,theproductswillbeputtedintoabox.Theproductswillbewashedbyhand.Itwillbringalotofchipsduringwashing.Wehadimplementedanewultrasonic

machinetowashproducts.Andwefoundtheyieldincreased.theyieldofGrindBeadproductsGB(六西格码项目Grindingprocess—WashingprocedurecanimpacttheChipscraprate.

KPIV3:Machinepictureisasbelow.theyieldofGrindBeadproductsGB(六西格码项目ProjectMetrics:ActualVsTargetComments:

Theyieldincreasedto87%.YieldBaseline77.5%theyieldofGrindBeadproductsGB(六西格码项目Summary–ConclusionConclusionfromactionitems

WevalidatedfourKPIVswhichhaveobviousimpacttodefectrate,wehadfinishedimprovementactionsandupdaterelateddrawinganddocuments.Throughtheseactions,wereducedthescrapratefrom22.5%to12.84%.theyieldofGrindBeadproductsGB(六西格码项目LairdTechnologiesSixSigmaGBProject

ControlPhaseIncreasetheyieldofGrindBeadproducts-GBtheyieldofGrindBeadproductsGB(六西格码项目KPIVControlPlanSummaryKPIVDetailProposedControlAction/PlanFrequencyPerson-In-Charge1Pressingprocess—Pressingcondition(SPI)Toolingwillbedamagedlittlebitafter1or2weeks.Fornewtooling,thesampleswillbetriedfiring.Pressingconditionneedtobemonitoringweekly.Weekly******2Firingprocess—TemperaturesettingsToohightemperature.Operatorschecktheactualtemperature.Daily******3Grindingprocess—WashingprocedureChangedtouseultrasonicmachinetowashproducts.OperatorsfollowtheWI.Daily******4Managementprocess—SourcingchainFollowup