6s project.ppt

8/10/2019 6s project.ppt

1/17

3/ 12/ 2003 CONFIDENTIAL


2/17

CONFIDENTIAL

Project title

Reduce the NPI pilot run

setup time in SMT lines

6


3/17

CONFIDENTIAL

Definition:

The NPI pilot run setup time in SMT lines,which is defined as the total time from SMTdepartment stops building the prior model to SMTdepartment starts to build the first board ofbalance quantity of NPI (except the sampleboards, normally 4pcs).


4/17

CONFIDENTIAL

0100

200300400

500

600700

800

Mar'04 Apr'04 May'04 Jun'04 Jul'04

U s e

d t i m e

( m i n )

Loading Tape board Sample board W/S Test

Target:360min

678

Primary Metric

742


5/17

CONFIDENTIAL

Process Mapping

Tape board Pass? Sample board Check Pass?Yes

Yes

No No

Build

Loading Check

Pass?Yes

No

FCTPass?Yes

No

W/S(If necessary)

ICT

Remark: non-value station


6/17

CONFIDENTIAL

Problem 1 & SolutionItem Problem Root cuase Solution

1

In A26117-01C1 build, Jun.105 min wasted for awaitingmaterials

Communication

2In 1591-719-5-A build, Jun. 80

mins to wait for material.Communication

3

In A26116-01C build, June.60 min to wait for material (use 3160622000AYS toreplace 3160619100AYS).

Communication

leader in time with last informations,and leader makes the last decisionand inform team in time, such as re-schedule NPI for material shortage

4

In C54T02P04 build, June. Westop NPI in tape boardbecause of PCB quality issue.

Communication

prior to SMT loading, start to buildNPI balance quantity withoutsample board result but have the FAreport of sample board from TEdepartment, etc.

Have not the smoothcommunications between internalteam member each other, so weappoint ME colleague to be teamleader for all NPI run, that is, the

relevant team members report to


7/17

CONFIDENTIAL

The responsibility of NPI team leader

1. Act as the team leader after Prog department held thekick-off meeting of NPI.

2. Push team members to complete his/her departmentaltask and have them to report the status to team leader.

3. Hold the NPI meeting to review team member's progress ifnecessary.4. Make the final decision if there are different opinions

among team members.5. Push Material department to prepare the materials and

inform Prod department to pick up materials from Store. Else,when material shortage or quality issue required 4 hrs toresolve prior to NPI build, team leader needs to inform PCdepartment to re-schedule NPI build.


8/17

CONFIDENTIAL

The responsibility of NPI team leader(continued)

6. Inform relevant departments to stop NPI or re-scheduleif there are some accidents in NPI process, for example,

material quality issue in NPI process, etc.7. If sample board test failed and TE has submitted the FAreport, team leader needs to inform SMT to build or notaccording to the FA report & team members' suggestion.

8. Summarize the FA (First Article) report and submit toteam members.

9. Hold the close meeting for preparation of massproduction after NPI completed.


9/17

CONFIDENTIAL

Problem 2 & Solution

Item Problem Root cuase Solution

Tape Board test will be parallel with Sample boardbuild to eliminate the non-value action, that means,

EE & IPQA check the component's orientation,stuffed component and non-stuff location usingaccording to the template or assembly drawing after EE builboard, if no problem found, notify EE to continue tobuild sample board (normally 4pcs), at the sametime, EE & IPQA continue to test the tape board.

However, production run is not allow withoutcompletion of the tape board testing.

1

About 300 minutes average for tape board, but we use 210minutes to check tape boardamong them.

Non-value


10/17

CONFIDENTIAL

Tape boardCheck orientationstuffed componentnon-stuff location

Check componentvalue

Build sampleboard

Tape board

Check componentvalue

Before:

Current:Build sample

boardCheck orientationstuffed componentnon-stuff location

Problem 2 & Solution (Continued)


11/17

CONFIDENTIAL

Problem 3 & Solution


1. ME draw out the master list of W/S parameters for reference.2. Directly run the 4pcs sampleboards at once and manual solderingif necessary

1 About 80minutes averagefor W/S.

Non-value

(Run a piece of sample board, andthen adjust the relevant parametersof WS machine, afterward, runanother sample board, and thenadjust the relevant parameters again,

and run other 2pcs sample board likethis.)


12/17

CONFIDENTIAL

AssemblyRun the first

sample board

Adjustparameters

of W/S

Before:

Adjustparameters

of W/S

Run theSecond

sample board

Current:

AssemblyDirectly run the 4pcs

sample boards atonce.

Adjust parameters accordingto the master list drew by ME

dept.

Problem 3 & Solution (Continued)


13/17

CONFIDENTIAL

Problems 4 & Solution

FA target < 500pcs components need 1 hrs500---1500pcs components need 1.5 hrs>1500pcs components need 2 hrs


1

About 120minutesaverage for teststation.

Non-value

(We must have the result of sampleboards test and then start to buildNPI boards, actually, somedefectives are not impact SMT tobuild, such as open, short,etc.)

If the sample board test fail, TEanalyze them and submit the FAreport to team. If the defects justlike open/short, team leader willinform SMT to build according to theFA report, at the same time, TEcontinue to re-debug & re-test tilltest ass.


14/17

CONFIDENTIAL

Test fail

Before:

FA Re-debug Re-test Test pass Inform SMTto build

Current:

Test fail FA

Re-debug Re-test Test pass

Inform SMTto build

Problems 4 & Solution (Continued)


15/17

CONFIDENTIAL

Problems 5 & Solution

SMT changes line as soon as they complete

the 4pcs sample boards, if TE department has notthe golden sample to debug test program/fixtureprior to NPI build.


16/17

CONFIDENTIAL

The micro process mapping


17/17

CONFIDENTIAL

NPI setup time in SMT lines

0

100

200

300400

500

600

700

800

Mar'04 Apr'04 May'04 Jun'04 Jul'04 Aug'04 Sep'04 Oct'04 Nov'04 Dec'04

U s e

d t i m e

( m i n )

Loading Tape board Sample board W/S Test

395

480

736742678

400 390 397

6s project.ppt

Documents

Transcript of 6s project.ppt