LEADERNG SWEE CHER

(SUPERVISOR)

MEMBERFAUZIAH

(LEADER JUNBILINE)

MEMBERLEE YOKE WAH

(LEADER MAINLINE)

MEMBERAZHANI

(LEADER MANUALLINE)

MEMBERNORFAEZAH

(LEADER CALENDAR LINE)

SUB LEADERROZIDAH

(LEADER KENSALINE)

MEMBERMOHD SAKRI

(SENIOR

TECHNICIAN)

MEMBERMOHD NASAHA

(SENIOR TECHNICIAN)

Why?2nd Highest F-cost in Assembly.Future plan of first QC project.

Top Reject in Assembly.

1# UKE

1# UKE REJECT REDUCTION

C rys talT o R educ e C os t of 1# Uke R ejec t P art T o R educ e 1# Uke R ejec t R ate

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4P lanAc tualP lanAc tualP lanAc tualP lanAc tualP lanAc tualP lanAc tualP lanAc tualP lanAc tualP lanAc tualP lanAc tualP lanAc tual

AC T ION

F ull Implementation

DOS olution Implementation

AL L

C HE C K R es ult Monitoring

S tandardization AL L

F uture P lan AL L

S ep-14

P roblem Analys is AL L

AL L

P ICAC T ION IT E M

AL L

P roblem Verific ation AL L

R ec ommend Ac tion for Improvement

AL L

Nov-14 Dec -14

P L AN

T heme S elec tion AL L

Data C ollec tion AL L

T arg et S etting AL L

Oc t-14Aug -14

T heme:Apr-14 May-14 J un-14J an-14 F eb-14 Mar-14 J ul-14

C irc le Name:Objec tive:

Legend: Plan

Actual

Pareto Diagram for 1# UKE REJECT (Before)

0.27%

0.02% 0.02% 0.01%

0.06%

858277

71

0.00%

0.05%

0.10%

0.15%

0.20%

0.25%

0.30%

0.35%

Tai Kizu Tai dirty / stain Tai dent Tai bend Others

Reject Rate

0

20

40

60

80

100Percentage (%)

1# UKE(Data of Jan’14 to Jun’14)

Pareto Diagram for 1# UKE REJECT (Before)

0.27%

0.02% 0.02% 0.01%

0.06%

7177

8285

0.00%

0.05%

0.10%

0.15%

0.20%

0.25%

0.30%

0.35%

Tai Kizu Tai dirty / stain Tai dent Tai bend Others

Reject Rate

0

20

40

60

80

100Percentage (%)

Tai Kizu

(Data of Jan’14 to Jun’14)

START

Dashinki Kumi Process

END

Jiita Junbi Process

Tsutsukana Junbi Process

1# Uke Junbi Process

Zara-Omotte Process

Zara-Ura Process

Tenpu Junbi Process

Furitsuke Process

Hodo Chosei Process

Jido Maki Kumi Process

Karenada Kumi Process

Higuruma Osae Junbi Process

Koteinai Kensa Process

Chuck dirty

Stopper spoil

METHOD

MACHINE

MAN

MATERIAL

No guide line for pincer condition

1# Uke Reject

1# Uke Bowl Jam

Neji P&P unit badset

Stocker jam

1# Uke pick up with spoil pincers

1# Uke Tray jam

Loosen Neji slippery

1# Uke P&P unit mis-chuck

Screw driver holding not straight

1# Uke Hanten unit P&P failure

2# Tsutae Guruma setting unit's failure

Driver cap wear off

Driver tip wear off

1# Uke unable to set evenly

on Jiita

Lack of skill

Sensor dirty

Air cylinder spoil

1# Uke out of position

1# Uke tray spoil

Solenoid dirty

Tsume Reba Opener too low

Part drop to conveyor

Tsume Reba Opener no proper jig

Air cylinder

spoil

Conveyor speed inconsistence

KTS position checker

malfunction

Vibration strong

Air pressure insufficient

Vacuum inconsistence

Pallet spoil

Turning bar too long

Mov't float

1# Uke Sori

1# Uke CD out

Incoming part spoil

Part easy Kizu

Lack of practice

OJT not thorough Judgment error

New manpower

Not follow instruction

Stubborn

Not sufficient guidance

Shortage of chance to

perform OT

Stress on working environment

Indirect work is relatively high

Careless

Not healthy

Not sufficient

Tired in routine work

Manpower shortage

Communication breakdown

Foreign worker

Language barrier

Vacuum

weak

Life span over

Driver cap dirty

Kobako mis-Winding

Jig design weakness

Stopper spoil

Sensor malfunctionSensor spoilSensor dirty

Stopper JamScrew driver size incorrect

MANMAN

METHODMETHOD

MACHINEMACHINE

MATERIALMATERIAL

Factor Problem Verification Result Comment PICNot sufficient guidance O New manpower is guide by operator Ng SC

Judgment error O Inspector miss-judge the 1# Uke Rozidah

Language barrier O Foreign worker unable to well understand Malay language Sakri

Tired in routine work O Part frequently got various reject Nasaha

Tsume Reba Opener no proper jig O The jig is handmade by line technician Fauziah

Vacuum inconsistence O Vacuum supply is variance from -54 to -45 Cm Hg. Lee YW

Chuck dirty O 1# Uke pick up chuck is dirty & oily Azhani

Conveyor speed inconsistence O The speed controller or conveyor is unable to lock Norfaezah

Driver cap wear off O Driver cap wear off & cause 1# Uke Kizu Ng SC

Driver tip wear off O Driver tip wear off & cause 1# Uke Kizu Rozidah

Pallet spoil O Spoil pallet cause the Hanten unit miss-chucking & part drop Sakri

Stopper spoil O Spoil stopper unable to proper lock the pallet Nasaha

Air cylinder spoil O Spoil air cylinder cause the tray jam Fauziah

Vibration strong O The vibration of PF bowl is inverse proportion to part quantity Lee YW

Screw driver size incorrect O Incorrect screw driver size is causing 1# Uke Kizu during dismantle Neji Azhani

No guide line for pincer condition O Operator is not aware the pincer can cause the 1# Uke spoil Norfaezah

1# Uke Sori O 1# Uke easily drop from mov't if Sori Ng SC

Part easy Kizu O The part is Kizu during the mov't assemble process Rozidah

Man

Machine

Method

Material

Criteria: Urgent, Cost and Ability

1 Not sufficient guidance 1 Line Leader to fully guide the new manpower

2 Display picture of Good & No Good part

3 Establish sample of reject

3 Language barrier 4 Teach with picture to explanation the job

4 Tired in routine work 5 Simplified the inspection job

5 Tsume Reba Opener no proper jig 6 Bench mark a standard jig

6 Vacuum inconsistence 7 Install vacuum regulator

7 Chuck dirty 8 Weekly inspection & clean of chuck

8 Conveyor speed inconsistence 9 Improvement on conveyor system

9 Driver cap wear off 10 Weekly inspection & clean of driver cap

10 Driver tip wear off 11 Weekly inspection & clean of driver tip

11 Pallet spoil 12 Replace with new pallet

12 Stopper spoil 13 Periodical change the stopper

13 Air cylinder spoil (for 1# Uke tray) 14 Inspection & replace new air cylinder once tray jam

14 Vibration strong 15 Set the guide line of feed the part to the PF bowl

15 Screw driver size incorrect 16 Standard the size of screw driver

16 No guide line for pincer condition 17 Set the guide line of good pincer condition

17 1# Uke Sori 18 Install guide during 1# Uke setting

18 Part easy Kizu 19 Use specify pincer to handle the part

Judgment error2

S/N Problem Selected Propose SolutionS/N

1 Line Leader to fully guide the new manpower Fauziah 01-05-14

2 Display picture of Good & No Good part Lee YW 01-05-14

3 Establish sample of reject Rozidah 01-05-14

4 Teach with picture to explanation the job Fauziah 01-05-14

5 Simplified the inspection job Azhani 01-07-14

6 Bench mark a standard jig Nasaha 01-07-14

7 Install vacuum regulator Sakri 01-07-14

8 Weekly inspection & clean of chuck Norfaezah 01-06-14

9 Improvement on conveyor system Ng SC PENDING10 Weekly inspection & clean of driver cap Lee YW 01-06-14

11 Weekly inspection & clean of driver tip Sakri 01-06-14

12 Replace with new pallet Ng SC 01-06-14

13 Periodical change the stopper Sakri 01-07-14

14 Inspection & replace new air cylinder once tray jam Nasaha PENDING15 Set the guide line of feed the part to the PF bowl Fauziah 01-07-14

16 Standard the size of screw driver Rozidah 01-06-14

17 Set the guide line of good pincer condition Azhani 01-07-14

18 Install guide during 1# Uke setting Sakri 01-07-14

19 Use specify pincer to handle the part Azhani 01-07-14

IMPROVEMENT ACTIVITIES PIC IMPLEMENT DATE

TRY SOLUTIONEstablish Reject

Sample1

MISS - JUDGE

To review inspectors judgment on appearance defect

TRY SOLUTIONInstall Standard Jig for Tsume Reba

Opener2

OLD TYPE

NEW TYPE

TSUME REBA OPENER

KENPAI REJECT REDUCE FROM 4.71% to 3.02%

To Improve 2# Tsutae Guruma Part Setting

3

TRY SOLUTIONInstall Vacuum Regulator at FA Junbi

Line

VACUUM REGULATORVACUUM REGULATOR

GUIDE LINE

VACUUM SENSOR ERROR REDUCE

To improve and stabilize vacuum pressure

TRY SOLUTIONChange New Pallet for I#

Uke Junbi machine4

KENPAI REJECT REDUCE FROM 3.23 % to 2.02%

To improve 1# Uke part Setting

TRY SOLUTIONChange Stopper at Kobako Winding

process5

Scratches Cause By Winding Reduce

To improve Pallet Locating

TRY SOLUTIONSet guideline at Part

Feeder Controller6

GUIDE LINE

PART JAM AT BOWL REDUCE FROM 9 TIMES TO 1 TIME PER DAY

To stabilize 1# Uke Part Feeder Vibration

TRY SOLUTION7 Improve Screw Driver for

repair

1# UKE NEJI

Scratches due to Screw Driver Reduce from 42 pcs to 4 pcs per month

Use screw driver tip Ø1.4mm

TRY SOLUTION

HAND STOPPER

8

To prevent 1# Uke drop during Kamiawase process

Install Hand Stopper at Yudo Maruana Kamiawase Unit

TRY SOLUTION Improve Pincer Condition9

TIP ROUNDED

SHARP TIP

Scratches due to Pincer reduce from 21 pcs to 1 pc per month

Pareto Diagram for 1# UKE REJECT (Before)

0.27%

0.02% 0.02% 0.01%

0.06%

8582

7771

0.00%

0.05%

0.10%

0.15%

0.20%

0.25%

0.30%

0.35%

Tai Kizu Tai dirty / stain Tai dent Tai bend Others

Reject Rate

0

20

40

60

80

100Percentage (%)

Pareto Diagram for 1# UKE REJECT (After)

0.09%

0.01% 0.00% 0.01%

0

918881

0.00%

0.05%

0.10%

0.15%

0.20%

0.25%

0.30%

0.35%

Tai Kizu Tai dent Tai bend Others

Reject Rate

0

50

100

150

200

250

300

350Percentage (%)

1# Uke Reject %

71% REDUCTION

(Data of Jan’14 to Jun’14) (Data of Aug’14 to Dec’14)

REJECT REDUCE FROM 0.38% TO 0.11%

ITEMS MONTHLY YEARLY

1) REJECT COST (US$) USD 280 USD 3,357

2) REPAIR COST ($4.8/Hour) USD 273 USD 3,272

3) MANPOWER COST (US$) USD 249 USD 2,982

Copy Document No : WI - AS2 - 06

No Rev. No : 1

1# UKE PREPARATION PROCESS Date : 02-01-15

(FA 1# UKE JUNBI) Page No. : 1 of 1

Station

JA1F Set 1# Uke onto pallet. 1# Uke Setting condition.

1# Uke General appearance.

J1F Set Yudo Maru Ana Bane (Not for Cal 7S) Yudo Maru Ana Bane Setting condition

Position Yudo Maru Ana Bane (Not for Cal 7S) Yudo Maru Ana Bane General appearance

Set 3# Cap Jewel 3# Cap Jewel Upside down

Set 3# Osae Jewel 3# Osae Jewel Position

J2F Set 5# Cap Jewel 5# Cap Jewel Upside down

Set 5# Osae Jewel 5# Osae Jewel Position

J2B Set 1# Tsutae Guruma onto pallet 1# Tsutae Guruma Setting condition

Oil 1# Tsutae Guruma Hen Shin (S4) Oiling Position & Volume as WS Drawing

Set Tsume Reba onto 1# Tsutae Guruma Tsume Reba fully set onto 1# Tsutae Guruma

Oil 1# Tsutae Guruma Shin (S4) Oiling Position & Volume as WS Drawing

J1B Turnover 1# Uke & Set to 1# Tsutae Guruma 1# Uke Setting condition.

Oil 5# Taishin Ana Jewel (MA) Oiling Position & Volume as WS Drawing

Set C-Ring onto 1# Tsutae Guruma 1# Tsutae Guruma Agaki Spec = 2.6 ~ 9.4 su.

Oil Yudo Maru Ana Guruma slot (Not for Cal 7S) Oiling Position & Volume as WS Drawing

JA1B Oil Maru Ana Guruma center surface (Not for Cal 7S) Oiling Position & Volume as WS Drawing

Set 1# Uke Shita Za (Not for Cal 7S) Proper Setting to 272# & 273# Pin

Set 1# Uke Shita Za Neji - 272# (Not for Cal 7S) Neji Torque = 17.5 ±7.5 Nmm

Oil 3# Taishin Ana Jewel (MA) Oiling Position & Volume as WS Drawing

JA1U Turnover 1# Uke & Set onto Tray Guide the 1# Uke Tray 1# & 62# Pin

Inspector Check Point

Check the 1# Uke Kizu with Z - Lamp During 1# Uke Omotte Turning Process

Kizu Limit judgment Refer to Pictures & Defectives sample

History : Prepared Approved

Rev 1: Add Inspection method

Fauziah Ng SC Normaya

Verified

INSTRUMENTS TECHNOLOGY (J) SDN. BHD.

WORK INSTRUCTION

TITLE :

TASK ELEMENT KEY POINT

21 Work Instruction of 1# Uke Preparation Process

(WI-AS2-06 Rev No: 1)

Work Instruction of Guidelines for Training New Manpower

(WI-AS2-042 Rev No: 0)Copy Document No : WI - AS2 - 42

No Rev. No : 0

TITLE : GUIDELINE FOR TRAINING NEW MANPOWER Date : 02/01/2015

Page No. : 1 of 1

S/No

1 Understand & Practice the Process Work Standard (WS) Explanation by Leader Level & above only.

2 Understand & Practice the Process Work Instruction (WI) Explanation by Leader Level & above only.

3 Understand & Practice the Process Control Standard (PCS) Explanation by Leader Level & above only.

4 Understand & Practice Assembly 2 Schedule Waste. Explanation by Leader Level & above only.

5 Understand & Practice Assembly Clean Room Rules Explanation by Leader Level & above only.

6 Read & Understand the Shop KPI (QCD report) Explanation by Leader Level & above only.

7 Understand the SH (Standard Hour) & AH (Actual Hour) Explanation by Leader Level & above only.

8 Daily Recording of Process Working Hours Leader to monitor the daily learning progress

9 Monthly summaries of Process Working Hours Leader to monitor the monthly learning progress

10 Proper operating procedure to Stereo Microscope Leader teaching by use WI no: WI-AS2-05

11 Proper practice on finger cot usage in Assembly production Leader teaching by use WI no: WI-AS1-60

to ensure the cleanliness of movement

12 Proper take care & periodically inspection on pincer. Leader to explain the care points of pincer

13 To report process abnormality to Leader immediately. Leader teaching by use WI no: WI-AS2-27

14 To raise question if any doubt Leader to act positively & encourage on

questions

History : Prepared Approved

Fauziah Ng SC Normaya

WORK INSTRUCTION

TASK ELEMENT KEY POINT

Verified

INSTRUMENTS TECHNOLOGY (J) SDN. BHD.

43 Weekly Machine Jig

Inspection Record Sheet

(No: ASSY 2 – 96a)

Monthly Machine Jig

Inspection Record Sheet

(ASSY 2 - 96b)

THANK YOU FOR YOUR ATTENTION! THANK YOU FOR YOUR ATTENTION!

ANY QUESTIONS?ANY QUESTIONS?