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DEFINE PHASE
Project Charter Project Background Metric Chart Baseline Data Savings Computation
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PROJECT CHARTER
Project Title: Reduction of Blo Holes defect in PICO fuses Problem Statement
On the current PICO fuse process , several inspector were being utilized to sort out cosmetic defect induced during coating process with blo holes as the top contributor. Reducing blo holes will result to reduction of inspection process.
Business Case
This project adheres to the core values and beliefs for continuous improvement through Lean Six Sigma strategies by elimination of non value added process and reducing scrap cost by 50% .
Goal Statement
To reduce blo holes defect from 1.6% to 0.8% July 2008 .
Financial Benefit
Annual savings of $114,000.
Stakeholders
Littelfuse Philippines Inc Associates
Ernesto Manuel
Time Line
Start Define and Measure Analyze and Improve Control Completion
Feb 2008 Feb 20,2008 March 20,2008 March 21,2007 June 21,2008 July 22, 2008 - Sept 2008 Oct 2008
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Fernando Arce , Noel Castillo , Jessie Dela Pena, Ruel A. , Quennie Laco .
Champion
Eduardo Bagadiong
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Current state
Identify waste
Future state
Implement
2004 PICO PRODUCTION AREA (24,010 sq ft) CYCLE TIME: 27 HOURS / FEET TRAVELLED: 525 FT
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PREMELT
VISUAL INS.
ASSEMBLY
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1 Sorter associate ( INSPECT fuses while on rolling on belt) - done 1 Reeler associate ( INSPECT cross fuses while on conveyor) 2 VI associate (INSPECT fuse on tape) Paper to tape ( TRANSFER fuse to paper tape for final packaging / 100% resistance TESTING)
127 ft
2 JI associate ,
re-INSPECT fuse
prior Final Audit
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BACKGROUND BACKGROUND
Visual Defect Breakdown
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BACKGROUND BACKGROUND
Scrap Reduction cost savings:
Monthly Projected Output: Baseline Data Target Projected monthly Saved Qty Unit Cost Monthly Savings
Annual savings
Labor cost savings:
$60,000.00
Inspection cost: 3000 / year for 1 associate Target number of inspection process to be remove: 3 associates / line ( a total of 6 lines ) = $ 54000
BACKGROUND
MEASURE PHASE
Operational Definition Detailed Process Map Attribute Agreement Analysis Baseline Metrics and Sigma Level
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Process Mapping
KPIV KPIV
Caps & Lead Solder Lead Caps & Lead CLI Track/ Harmonica Top / Bottom Tray Heat Set-up Glassing Pin Tray Turning Temperature Coating wheel Bend Fuse MM Fall Apart Fuse Bare Fuse Coating Rejects Damage Lead Good Fuse VI Escapee Rejects Good Fuse Damaged Lead VI Escapee Rejects Good Fuse Damaged Lead
TYPE TYPE
Process Process
KPOV KPOV
Quality of Caps & lead D-M-A-I-C Solder Weight/ No Melt / Empty Bend/ Exposed Copper
Premelt
Multimag (CLI)
C C C C
Wheelcoating VI
Coating Rejects Blo Holes Fallout Resistance defect VI Escapee Rejects Good Fuse VI Escapee Rejects Good Fuse Damaged Lead VI Escapee Rejects Good Fuse Damaged Lead
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Radial
Tegam
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BACKGROUND
MEASURE PHASE
DEFECT DEFINITION
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BACKGROUND
MEASURE PHASE
Attribute Agreement Analysis (3 inspectors using 25 Good / 25 Reject w/ 3 trial each )
AssessmentAgreement AssessmentAgreement
WithinAppraisers
80 75 70 Percent Percent 65 60 55 50 45 Hazel Qunnie Appraiser Tina 80 75 70
WithinAppraisers
95.0% CI Percent
95 90 85 Percent 80 75 70 65
95 90 85 Percent 80 75 70 65
95.0% CI Percent
Hazel
Qunnie Appraiser
Tina
Hazel
Qunnie Appraiser
Tina
# Matched: All appraisers' assessments agree with the known standard. Fleiss' Kappa Statistics Response A R Kappa SE Kappa Z P(vs > 0) 0.0000 0.0000
# Matched: All appraisers' assessments agree with the known standard. Fleiss' Kappa Statistics Response A R Kappa SE Kappa Z P(vs > 0) 0.0000 0.0000
conclusion: kappa level is only 0.68 , need to conduct eyeball correlation to correct judgment of inspectors.
conclusion: kappa level improved by 25% after eyeball correlation and now above 0.7 requirement . We can now proceed with the analyze phase. .
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BACKGROUND
MEASURE PHASE
5 why analysis on Blo Holes , Fallout and Coating defect
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BACKGROUND
MEASURE PHASE
Prioritization of possible root cause
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BACKGROUND
MEASURE PHASE
Baseline data
Sigma Performance
CURRENT
1 2 3 4 5
N= D= O=
Solve For Defects Per Million Opportunities Look Up Process Sigma In Abridged Sigma Conversion Table Sigma=
3.41
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BACKGROUND
ANALYZE PHASE
Validation of factors. Using Dorian Shainin methodology:
Dont let the engineer do the guessing Let the parts do the talking
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7 lbs min
0.115 max
P-Value = 0.00
P-Value = 0.03
Remarks: p-value<0.05, accept Ha: proportion A proportion B Conclusion: there is Significant difference exist , lower cap retention will result blo holes defect.
Remarks: p-value<0.05, accept Ha: proportion A proportion B Conclusion: there is Significant difference exist , lower cap top to cap top dimension will result to lesser blo holes defect.
SIGNIFICANT
Negative correlation exist between cap retention and cap top to cap top. Lower cap top will result to higher cap retention value . 19
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ANALYZE PHASE
X1 :Variation on Solder Weight Validation run: Build 2 sets of samples using solder weight with an average of 0.043 grams and 0.045 grams respectively. Compare the cap retention using hypothesis test .
BoxplotofCapretention( 0 .0 4 3 gvs.0 .0 4 5 g)
14 12 10 8 6 4
1 0 .0 2
capret ention
7 .5 0 6 6 7
P-Value = 0.00
2 0.043gcapret 0.045gcapret
Remarks: p-value<0.05, accept Ha: proportion A proportion B Conclusion: there is Significant difference exist , lower solder weight will result to lower cap retention.
SIGNIFICANT
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ANALYZE PHASE
X3: improper handling of trays during assembly process Validation run: Build 2 sets of samples using tray with bend upright (mis-align fuse condition ) and trays in a good condition. Compare the cap top using hypothesis test .
BoxplotofCaptoptocaptop( Misalignvs.ALignfuse)
0.125
0.115
0.11386
BEND UPRIGHT
0.110
0.108903
0.105
P-Value = 0.004
caprentionmisalignfuse Cap top mis-align fuse captopalignfuse Cap top align fuse
Remarks: p-value<0.05, accept Ha: proportion A proportion B Conclusion: there is Significant difference exist , lower solder weight will result to lower cap retention. SIGNIFICANT
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ANALYZE PHASE
X5 : Not optimize wheelcoater temperature setting
-Temperature are being adjusted to optimize the diameter , length of fuse and quality of cured epoxy powder .Fuse after curing process should pass acetone test and no significant change on resistance value of the fuse.
Shift to Shift variation on wheelcoater
2.8%
3.00% 2.50% 2.00% 1.50% 1.00% 0.50% 0.00% 471 ( optr A) 473 (Optr A) 471 ( optr B)
2.0%
CURRENT - defect increases during transition of single coating to double coating since NO define temperature setting per series (single or double coating ) . - Temperature specification is too wide
SIGNIFICANT
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BACKGROUND
IMPROVE PHASE
Hypothesis test for solder wt evaluation DOE on wheelcoater Hypothesis test for Coating Adjuster Improvement plan on Handling of trays
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Modified: -Less moving parts -adjustment of solder cut is base on digital controller integrated on servo motor - Rubber lining on both pinch wheels instead of on just one wheel - Spring loaded pinch wheels with adjustable spring load instead of pinching the solder wire thru set screw - rollers are equipped with bearings 24 P-Value = 000
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2.8%
3.00% 2.50% 2.00% 1.50% 1.00% 0.50%
2.1%
high resistance open fuse flyaway fallout Fallapart Blo holes
P-Value = 000
0.00% current Premelt Optimize Premelt
Using optimize premelt machine , projected reduction of defect related to solder weight is only at 0.7% . Cost of 1 machine: $3050 Total cost for 10 machines: $30500 ROI at 0.7% defect reduction: 9 months
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IMPROVE PHASE
Low Cpk of Solder Weight at Premelt Machine
Still OK
On current specification , defect such as blo holes , fallout and resistance are already being encountered even with just a shift of below 3 % from the nominal value Improvement plan: Shift the nominal solder weight specification by 11% , from 0.0045g to 0.0050g to compensate the variation of solder weight. This will improve the cap retention by approximately 25%.
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IMPROVE PHASE
Low Cpk of Solder Weight at Premelt Machine
Increase nominal solder weight specification from 0.045g to 0.050g ( 11% increase) to compensate variation of premelt operation.
defect related to solder will be reduced from 3.5% to 2.28% will have 1.2% reduction on defect. Supporting document: PCP 08-043
low resistance
open fuse flyaw ay coating defect fallout exposed solder Fallapart Blo holes
increasesolderwt summary
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IMPROVE PHASE
Not optimize wheelcoater temperature setting
-Temperature are being adjusted to optimize the diameter , length of fuse and quality of cured epoxy powder .Fuse after curing process should pass acetone test and no significant change on resistance value of the fuse. Note temperature should not exceed 300C (melting point of solder ) to avoid solder reflow.
CURRENT
- defect increases during transition of single coating to double coating since NO define temperature setting per series (single or double coating ) . - Temperature specification is too wide - Perform DOE :
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IMPROVE PHASE
X2 : Not optimize wheelcoater temperature setting DOE on Wheelcoater Temperature Design: 4 factors w / 2 level each
Pareto chart shows that Preheat has the most significant effect in reducing blo holes defect . Main effect graph shows that higher preheat will result to lesser blo holes.
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IMPROVE PHASE
Not optimize wheelcoater temperature setting
2.50% 2.00% 1.50% 1.00% 0.50% 0.00% Exposed cap fallout exposed solder Blo holes
old setting
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CONTROL PHASE
Summary of Corrective / Preventive Actions and Documentations SPC and Reaction Plan Trend Chart Acknowledgement
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WP107PICO MultimagTurningOperation
DOandDontsof handlingtrays
solderweight drawing
F9006 WheelcoaterTemperatureSettingl
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BACKGROUND
CONTROL PHASE
Update SPC Chart to Reflect change on Solder Weight specification from 0.0045g 5% to 0.0050 5% )
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BACKGROUND
CONTROL PHASE
Update SPC Chart to Reflect change on Cap retention specification from 7lbs min to 10 lbs min
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BACKGROUND
CONTROL PHASE
Generate Out of Control Reaction plan for Blo Holes and Exposed solder
BloHolesOCAP flow
Out of Control Action Plan will serve as systematic guideline for troubleshooting blo holes and exposed solder defect.
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BACKGROUND
CONTROL PHASE
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BACKGROUND
CONTROL PHASE
Intangible Benefits
Break traditional set up for PICO Wheelcoater process Application of Six Sigma Tools in doing Process Improvement. Develop TEAMWORK while ACHIEVING WORK SATISFACTION in making improvement
Tangible Benefits
$ 60,000 annual cost saving on scrap $ 54,000 annual savings on wages and fringes as a result of reduction of 10 sorter associates
Future Plans
Pursue Solder weight Cpk improvement as a greenbelt project
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BACKGROUND
Acknowledgement
The team would like to acknowledge our associates for sharing their genuine ideas and our fellow Technician and PE for their cooperation and during the evaluation run Also for the guidance of our superiors: Ms. Zorayda Zordilla Improvement Manager Mrs. Josephine Tablada - Production Manager Sir Ed Bagadiong Plant Manager Sir Dan Onken - Operations Director
To the management for giving us a chance to be part of LF 6 sigma culture There's always room for improvement, you know--it's the biggest room in the house."-Louise Heath Leber
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