TAPE & REEL SEAL TAPE QUALITY

GREEN BELT PROJECT: NLR-GB-J1302DIVISION: NLR-THERMISTORS

PLANT: BERMUDEZ IOSWALDO ALVAREZ – QUALITY ENGINEER

INITIAL SITUATION & OBJECTIVE

INITIAL• LOOSE TAPE – 3,611

PPMS.• COST TO COMPANY

25,292

OBJECTIVE• GOAL: 2000 PPMS.• STRETCH GOAL: 1000

PPMS

IMPACTED AREAS• TAPE AND REEL STATION – NEW SET-UP PARAMETERS• PRODUCTION – LESS RE-WORKS• MAINTENANCE – LESS MAINTENANCE CARDS• QUALITY – LESS LOTS• MATERIALS – CARRIER TAPE AND COVER TAPE USAGE• MACHINERY – NO INVESTMENT ON NEW EQUIPMENT

CURRENT SITUATION AFTER IMPROVEMENTS

Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-140

2000

4000

6000

8000

10000

4653

9279

36662029

3951

883

2941 28591900

946

PPMS for loose tape

Result Goal

GREEN BELT TOOLS USED• PROCESS MAP• FISHBONE DIAGRAM• XY DIAGRAM• MSA – RR• CPK• MULTIVARI• BOXPLOTS• INTERACTION PLOT• RESIDUALS• CUBE PLOT• OPTIMIZATION PLOT• CONTROL PLAN

• COMPLETE DOE: HIT TARGET FULL FACTORIAL DATA COLLECTION ANALIZE DRAW SOLUTION REPLICATE/VALIDATE IMPLEMENT SOLUTION

OTHER POSSIBLE PROJECTS IDENTIFIED

• ELECTRICAL TEST IN OIL BATHS, WE HAVE CURRENTLY SOME ESCAPES AND THE PROCESS IS TEDIOUS AND MONOTONOUS.

• COATING FOR THERMISTOR, WE HAVE A HIGH PPM ON COSMETIC DEFECTS AND THE CURRENT COATING PROCESS HAS NO IMPROVEMENTS SINCE IMPLEMENTATION ON THE 90’S.

• INKING FOR FILM PRODUCTS, THE MIXTURE AND APPLICATION OF INK FOR RESISTIVE VALUE HAS A LOT OF PARAMETERS TO CONTROL AND WE CURRENTLY HAVE HIGH SCRAP IN THIS AREA.

• MARKING FOR WIRE WOUND LVR PRODUCT, WE CURRENTLY HAVE HIGH PPMS DUE TO DEFECTIVE OR MISSING STAMP ON THESE COMPONENTS

FINAL COMMENTS AND EXPERIENCES

• ANALYSIS OF VARIATION (MULTIVARI)• INTERACTION PLOT (INTERACTION BETWEEN PARAMETERS)• BOXPLOTS (COMPARISON BETWEEN RESULTS OF SET-UPS)• THE WHOLE THING WITH THE DOE AND THE OPTIMIZATION PLOT