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1OESixSigmaProject
ToolingUseOptimization
StartDate : 01-09-2013Coach : XiangBillSponsor : WangFengProcessOwner : LiuYanqiProjectLeader : LiuYanqiTeamMembers : He,Meihua(MFG)
Li,Wenwei(TS)Gu,Tianhua(EM)
Ma,Jihao(QA)Zhang,Zhenyu,YuYongjia\MaoCindyEM=EngineeringandMaintenanceTS=TechnicalServicei-nexusID:293072ControlImproveAnalyzeMeasureDefineProblemStatement
Thebudgetoftoolingincreasedtoomuchandfor2014thebudgetofitis4,140KRMB,In2015wewillget5%cutbaseonthenormalincrease,about200KRMB.BusinessCase
Reducingthecostoftoolingwhilstmaintainingqualityandsupplyofproduct.GoalGoalMetricBaselineTargetEntitlementCostYearsaving(%)05%NA3CustomersToolingManagementOutputsProcessInputsSuppliersStartStopSIPOCControlImproveAnalyzeMeasureDefineMFGDirtyToolingHROperatorsDirtyToolingEHSDefectTabletsTS/EMDocumentationQATabletsReceiveUsedToolingCleaningPolishingandbuffingStoreCompressionMachine4ControlImproveAnalyzeMeasureDefineProcessMapofTooling–Moredetails?-OptionalSpecificationsNeed
DriversCTQsCurrentGoal
ServiceLifeLifeTimeCal
300BatchesCal
350batchesCost
reducetheannualcostoftoolingsaving%05%
QualityAQLPassPass
5WeneedtoreducethecostoftheTooling.(Sponsor)CTQKeyIssueVOCControlImproveAnalyzeMeasureDefineVOCYfortheprojectDefectDefinition: Lifetimeofpunchespernumberofbatches6ControlImproveAnalyzeMeasureDefineAnnualcostoftooling754=Costofnewsetofpunches(setof45)+costofreplacementofafewpunches(nodata)Annualcostoftoolingall6compressionmachines=Costofnewsetofpunches+costofreplacementofafewpunchesBysetof50or100punches6compressionmachine1yearbuyfor754x3setsof50Averagecostoftoolingperbatchoftablets(RMB)
theThroughenhancethemaintenanceanddataanalysisestimatetheservicelifeoftheTooling7ControlImproveAnalyzeMeasureDefineCostoftoolingUsepuncheslonger??8i-nexusID29307Title:
ToolinguseoptimizationBenefits:ReducethecostoftheToolingControlImproveAnalyzeMeasureDefinei-nexusSearch9ControlImproveAnalyzeMeasureDefineWhatquestionsdoyouwanttoanswer?123
What’sthereasonofthebadtooling4
Howlongistheservicelifeofabatchoftooling5
DataOperationalDefinitionandProcedures
WhatMeasureTypeDataTypeHowMeasuredRelatedConditionsSamplingNotes1
BadnumbersOutputdiscreteBatchnumbersissueEveryBatch2
ServiceLifeoutputdiscreteBatchnumbersnormalEveryBatch3
4
5
WhatareyourplansforGageR&R?Howwillyouplotthedatayoucollect?DataCollectionPlan10ControlImproveAnalyzeMeasureDefineDataCollectionPlan11ShowmeansthroughwhichmeasurementswereverifiedSOPPM-29ControlImproveAnalyzeMeasureDefineMeasurementSystemAnalysis12ForStock754theaverageservicelifeis300BatchesforCaland64BatchesforCen.ControlImproveAnalyzeMeasureDefineBaseline13ForFette3090theaverageservicelifeis355BatchesforCalD600and66BatchesforCenControlImproveAnalyzeMeasureDefineBaseline14ForKelianT400theaverageservicelifeis372BatchesforCalD600ControlImproveAnalyzeMeasureDefineBaseline15ForFette3200itheaverageservicelifeis58BatchesforCenControlImproveAnalyzeMeasureDefineBaseline16Thetooling(Cal)servicelifeon3090andT400arelongerthanon754ControlImproveAnalyzeMeasureDefine17Thetooling(Cen)servicelifeon3090islongerthanon754andFette3200iControlImproveAnalyzeMeasureDefine18ControlImproveAnalyzeMeasureDefineProcessCapabilityPpk754:0.73;T400:0.46;3090:0.49AllstabilityandnormalityGoodperformance19ControlImproveAnalyzeMeasureDefineProcessCapabilityPpk754:0.84;3090:0.96;3200:0.65Allstabilityandnormalityexcepton3200i20ControlImproveAnalyzeMeasureDefineCauseandEffectAnalysis20人機(jī)法環(huán)料模具材料批次差異使用前檢查方法不同人員技能水平差別大安裝操作不當(dāng)造成損壞保養(yǎng)方法不合理設(shè)備老化嚴(yán)重設(shè)備異常造成模具損壞人為判斷的經(jīng)驗(yàn)儲(chǔ)存環(huán)境物料異常人員意識(shí)工具不合適21People
Environment
Method
Materials
Machine
Measurement
PotentialRootCausesControlImproveAnalyzeMeasureDefine22ControlImproveAnalyzeMeasureDefineHypothesisTestingShowMinitabsessionfolder+graphsscreenshots–commentbottomofslidesCheckstabilityandnormalityTwo-sampleTforContaminationSupplierNMeanStDevSEMeanItalien60,112170,009390,0038Korea60,141830,007910,0032Difference=mu(Italien)-mu(Korea)Estimatefordifference:-0,0296795%CIfordifference:(-0,04101;-0,01833)T-Testofdifference=0(vsnot=):T-Value=-5,92P-Value=0,000DF=9KoreaissignificantlyhigherthanItalien
23ControlImproveAnalyzeMeasureDefineRegressionAnalysisShowMinitabsessionfolder+graphsscreenshotsCheckresidualsassumptionsSummarycommentatbottomofslide24ControlImproveAnalyzeMeasureDefineDOEShowMinitabsessionfolder+graphsscreenshotsCheckresidualsassumptionsSummarycommentatbottomofslide25IdentifiedRootCausesListidentifiedrootcausesControlImproveAnalyzeMeasureDefine26SelectedSolutionsControlImproveAnalyzeMeasureDefineHighlightSelectedSolutions27ControlImproveAnalyzeMeasureDefineRiskAssessmentListdetails28ControlImproveAnalyzeMeasureDefinePilotandImplementationPlanListdetails29StandardisationandDocumentationControlImproveAnalyzeMeasureDefineListdetailsofprocedures,templates,manufacturinginstructionsetc…,andwhenapprovedforuse,mmm/yyyyListdetailswhentrainingcompleted,mmm/yyyy30ResultsUsethetablebeloworuseabeforeandaftergraph.Summarycommentatbottomofslide.ControlImproveAnalyzeMeasureDefineGoalMetricBaselineTargetCurrentIncreaseABCYieldMonthlyABCYield(%)50.2(average)(JantoJun2011)≥60.0(average)65(average)(AugtoSept2011)01020304050607080Number
of
guarantee
claims
due
toleakageNov-99Jan-00Mar-00May-00Jul-00Sep-00Nov-00Jan-01Mar-01May-01Jul-01Sep-01Nov-01Jan-02Mar-02May-
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