六西格玛项目模板-英文ppt课件.pptx

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1、六西格玛优质项目：六西格玛优质项目：Reduce TMOV surface contaminationReduce TMOV surface contamination 2018.12.5 2018.12.5D-stage catalogueD-stage catalogueContinuouslyImprovingCMAIDD-1D-1 BackgroundBackgroundD-2 ProjectD-2 Project TargetTargetD-3 ProjectD-3 Project TeamTeamD-4 ProjectD-4 Project ScheduleScheduleD M

2、AICD-1D-1 BackgroundBackgroundD M AICCurrent Situation1. The surface contamination issue is the one of the top three rejected by FQA sampling, FQA rejected 23 lots in 2017. 2. There is a surface contamination customer complain in January 2018.D-2D-2 Project TargeProject Target tBaselineTargetCurrent

3、 situationCurrent situationD M AICRejected lots:23Rejected lots:15D-4 Project ScheduleD-4 Project ScheduleD M AIC2018ItemPhaseWK14WK15WK16WK17WK18WK19WK20WK21WK221Define2Measure3Analyze4Improve5Control6Project reviewD-5D-5 Voice of CustomerVoice of CustomerD M AIC $66,676.76, 20.11% 1.Test and Print

4、2.Visual operator3.FQA Internal Customer All MOV End Customer External Customer1.Improve customer satisfaction2.Better Quality3.Faster reaction speed 4.Delivery EfficiencyExternal VOCInternal VOC1.Lower scrap cost2.Higher productivity3.Better Quality4.Better Improve SalaryM-stage CataloguM-stage Cat

5、alogue e $66,676.76, 20.11%D M AICContinuouslyImprovingCMAIDM-1 Process Flow Chart M-1 Process Flow Chart M-2 Plato Chart of DefectsM-2 Plato Chart of DefectsM-3 MSA-3AM-3 MSA-3AM-1 Process Flow Chart M-1 Process Flow Chart D M AIC $66,676.76, 20.11%CuringCoating Key ProcessLaser MarkingAssemblyVisu

6、al checkPackingFQA samplingElectrical TestSemi finished appearanceStorageShippingM-2 M-2 The scrappage of 14D surface contamination tendency chart D M AIC系列10.49%0.57%0.52%0.53%2017年12月2018年1月2018年2月平均0.49%0.57%0.52%0.53%0.44%0.46%0.48%0.50%0.52%0.54%0.56%0.58%The scrappage of 14D surface contaminat

7、ion tendency chart M-3 MSA-3A before trainingM-3 MSA-3A before trainingD M AICPart NoTMOV seriesPart NameTMOV seriesSpecifications:Reference visual standardOperator 1Zhang RuixiaOperator 2Liu JianxueOperator 3Deng ChaolianOperator 4Lu ChunlanTrials2 timesM-3 MSA-3A before trainingM-3 MSA-3A before t

8、rainingD M AIC4 43 32 21 11 10 00 09 90 08 80 07 70 06 60 0A Ap pp pr ra ai is se er rP Pe er rc ce en nt t9 95 5. .0 0% C CI IP Pe er rc ce en nt t4 43 32 21 11 10 00 09 90 08 80 07 70 06 60 0A Ap pp pr ra ai is se er rP Pe er rc ce en nt t9 95 5. .0 0% C CI IP Pe er rc ce en nt tD Da at te e o of

9、f s st tu ud dy y: : R Re ep po or rt te ed d b by y: : N Na amme e o of f p pr ro od du uc ct t: : MMi is sc c: : A As ss se es ss smme en nt t A Ag gr re ee emme en nt tWWi it th hi in n A Ap pp pr ra ai is se er rs sA Ap pp pr ra ai is se er r v vs s S St ta an nd da ar rd dM-3 MSA-3A before trai

10、ningM-3 MSA-3A before trainingD M AIC决定测量系统Kappa 值有效性错误率错误警报率评价人可接受的条件大于等于0.7580%010%Operator 10.4475020.7%Operator 20.4677020.7%Operator 30.168030.1%Operator 40.1668028.3%3A conclusion:All operator are failing for the 3A test before trainingD M AICA-1 Fishbone diagram analysisA-2 Category ratio of

11、surface contamination A-3 Surface contamination analysis ContinuouslyImprovingCMAIDA-stage CatalogA-stage CatalogA-1 Fishbone Diagram AnalysisA-1 Fishbone Diagram AnalysisSurface Contamination AnalysisD M AICncontaminatiosurfaceEnvironmentMeasurementsMethodsMaterialMachinesPersonnelmachine in timeth

12、e encapsulationOperator do not clearbeen damagedSteel-Wire Screen hasmachine is not sharpThe cutter of the 3 in 1Paper tape is fragilemachine is wrongencapsulatingThe way to clean thestandardinspection is notThe process of visualmethod is not accurateThe measurementmisjudgmentVisual inspectionC Ca a

13、u us se e- -a an nd d- -E Ef ff fe ec ct t D Di ia ag gr ra ammA-2 A-2 Category ratio of surface contamination 240pcs of products were randomly selected for statistical analysisD M AIC数量143532024占比59.58%22.08%8.33%10.00%PaperbattingMisjudgmentothers14353202459.58%22.08%8.33%10.00%0.00%10.00%20.00%30

14、.00%40.00%50.00%60.00%70.00%020406080100120140160Category ratio of surface contamination 数量占比A-3 A-3 Surface contamination analysisPaper analysisD M AICThe source of the paper scraps is the paper tape.A-3 A-3 Surface contamination analysisPaper analysisD M AICFactorLevelResponsePaper ScrapCutter pre

15、ssureDrying agentTargetAs little as possibleCutter shape5.5kPA7.5kPAYesNoStraightArcA-3 A-3 Surface contamination analysisDOE data collectionD M AICStdOrderRunOrderCenterPtBlocksPressuedrying agentshapedefect6111highnostraight215211lownostraight323311lowyesarc747411lowyesstraight294511highyesarc6186

16、11highyesstraight191711lownoarc902811highnoarc63A-3 A-3 Surface contamination analysisPaper analysisD M AICT Te er rmmA AC CB BA AC C1 14 41 12 21 10 08 86 64 42 20 0A AP Pr re es ss su ue eB Bd dr ry yi in ng g a ag ge en nt tC Cs sh ha ap pe eF Fa ac ct to or rN Na amme eS St ta an nd da ar rd di

17、iz ze ed d E Ef ff fe ec ct t3 3. .1 18 8P Pa ar re et to o C Ch ha ar rt t o of f t th he e S St ta an nd da ar rd di iz ze ed d E Ef ff fe ec ct ts s( (r re es sp po on ns se e i is s d de ef fe ec ct t, , = = 0 0. .0 05 5) )Coded CoefficientsTerm Effect Coef SE Coef T-Value P-Value VIFConstant 48

18、.63 1.71 28.40 0.000Pressue -15.25 -7.63 1.71 -4.45 0.021 1.00drying agent -5.75 -2.87 1.71 -1.68 0.192 1.00shape -46.75 -23.37 1.71 -13.65 0.001 1.00Pressue*shape 4.75 2.37 1.71 1.39 0.260 1.00Regression Equation in Uncoded Unitsdefect = 48.63 - 7.63 Pressue - 2.87 drying agent - 23.37 shape + 2.37

19、 Pressue*shapeConclusion：The experiment of affecting paper scrap, we can know that the shape and pressure are the significant factor (P0.05, All subgroups have a normal distribution0 0. .0 00 04 42 20 0. .0 00 04 40 00 0. .0 00 03 38 80 0. .0 00 03 36 60 0. .0 00 03 34 40 0. .0 00 03 32 20 0. .0 00

20、03 30 00 0. .0 00 02 28 80 0. .0 00 02 26 69 99 99 95 59 90 08 80 07 70 06 60 05 50 04 40 03 30 02 20 01 10 05 51 1MMe ea an n0 0. .0 00 03 34 44 4S St tD De ev v0 0. .0 00 00 02 29 96 66 6N N5 5A AD D0 0. .2 23 34 4P P- -V Va al lu ue e0 0. .6 61 11 11 10 00 0P Pe er rc ce en nt t1 10 00 0 mme es s

21、h h n nu ummb be er rN No or rmma al l 0 0. .0 00 04 45 50 0. .0 00 04 40 00 0. .0 00 03 35 50 0. .0 00 03 30 09 99 99 95 59 90 08 80 07 70 06 60 05 50 04 40 03 30 02 20 01 10 05 51 1MMe ea an n0 0. .0 00 03 36 6S St tD De ev v0 0. .0 00 00 03 36 60 06 6N N5 5A AD D0 0. .2 20 09 9P P- -V Va al lu ue

22、 e0 0. .7 71 14 48 80 0P Pe er rc ce en nt t8 80 0 mme es sh h n nu ummb be er rN No or rmma al l 0 0. .0 00 06 60 00 0. .0 00 05 58 80 0. .0 00 05 56 60 0. .0 00 05 54 40 0. .0 00 05 52 20 0. .0 00 05 50 00 0. .0 00 04 48 89 99 99 95 59 90 08 80 07 70 06 60 05 50 04 40 03 30 02 20 01 10 05 51 1MMe

23、ea an n0 0. .0 00 05 53 38 8S St tD De ev v0 0. .0 00 00 02 25 58 88 8N N5 5A AD D0 0. .1 17 75 5P P- -V Va al lu ue e0 0. .8 84 42 26 60 0P Pe er rc ce en nt t6 60 0 mme es sh h n nu ummb be er rN No or rmma al l D M AICA-3 A-3 surface contamination analysis8 80 06 60 01 10 00 00 0. .0 00 01 10 00

24、0. .0 00 00 09 90 0. .0 00 00 08 80 0. .0 00 00 07 70 0. .0 00 00 06 60 0. .0 00 00 05 50 0. .0 00 00 04 40 0. .0 00 00 03 30 0. .0 00 00 02 2P P- -V Va al lu ue e0 0. .7 79 96 6P P- -V Va al lu ue e0 0. .8 89 95 5MMu ul lt ti ip pl le e C Co om mp pa ar ri is so on ns sL Le ev ve en ne e s s T Te e

25、s st tmme es sh h n nu ummb be er rT Te es st t f fo or r E Eq qu ua al l V Va ar ri ia an nc ce es s: : y yi ie el ld d v vs s m me es sh h n nu um mb be er rMMu ul lt ti ip pl le e c co om mp pa ar ri is so on n i in nt te er rv va al ls s f fo or r t th he e s st ta an nd da ar rd d d de ev vi ia

26、 at ti io on n, , = = 0 0. .0 05 5If intervals do not overlap, the corresponding stdevs are significantly different.方差齐性检验: P-Value =0.796 0.05Variances are equal!各样本总体方差相等，即满足方差齐性，可以使用单因素方差分析法Test for Equal Variances: yield versus mesh number MethodNull hypothesis All variances are equalAlternative

27、 hypothesis At least one variance is differentSignificance level = 0.0595% Bonferroni Confidence Intervals for Standard Deviations meshnumber N StDev CI 100 5 0.0002966 (0.0000823, 0.0020526) 60 5 0.0002588 (0.0000769, 0.0016726) 80 5 0.0003606 (0.0001019, 0.0024468)Individual confidence level = 98.

28、3333%Tests TestMethod Statistic P-ValueMultiple comparisons 0.796Levene 0.11 0.895D M AICA-3 A-3 surface contamination analysis8 80 06 60 01 10 00 00 0. .0 00 06 60 00 0. .0 00 05 55 50 0. .0 00 05 50 00 0. .0 00 04 45 50 0. .0 00 04 40 00 0. .0 00 03 35 50 0. .0 00 03 30 0mme es sh h n nu ummb be e

29、r ry yi ie el ld dB Bo ox xp pl lo ot t o of f y yi ie el ld dAnalysis of VarianceSource DF Adj SS Adj MS F-Value P-Valuemesh number 2 0.000012 0.000006 61.03 0.000Error 12 0.000001 0.000000Total 14 0.000013Model Summary S R-sq R-sq(adj) R-sq(pred)0.0003082 91.05% 89.56% 86.01%Meansmeshnumber N Mean

30、 StDev 95% CI100 5 0.003440 0.000297 (0.003140, 0.003740)60 5 0.005380 0.000259 (0.005080, 0.005680)80 5 0.003600 0.000361 (0.003300, 0.003900)Pooled StDev = 0.000308221 通过上图方差分析箱型图和p 值 小于0.05，说明这三个组间至少有两个组之间是存在显著性差异的，即网格目数对杂物率有影响cotton wool analysisD M AICThe source of the cotton wool is1)The opera

31、tors gloves will be left with cotton wool when they touch the product.2)The cotton wool on the encapsulation machine will fall into the equipment.A-3 A-3 surface contamination analysisD M AICI-1 Paper ImprovementI-2 Steel-Wire Screen ImprovementI-3 Cotton wool ImprovementI-4 Detection improving Cont

32、inuouslyImprovingCMAIDI-stage CatalogI-stage CatalogD M AICCutter shape ImprovementI-1I-1 Paper Improvement1.Modify all the cutter shape, and increase the contact area between the cutter and the paper tape.2.Adjust cutting tool pressure to 7.5KPaD M AICBefore ImprovementI-1I-1 Paper Improvement Afte

33、r ImprovementCutter shape ImprovementD M AICSteel-Wire Screen ImprovementI-2I-2 Steel-Wire Screen Improvement1.Buy the new Steel-Wire Screen(80 mesh) instead of that one damaging(100 mesh).2.Require weekly take out the epoxy power from encapsulation tank and screen out the contamination.D M AICcotto

34、n wool ImprovementI-3I-3 cotton wool Improvement1.Replace the wool free gloves for operator. 2.Require weekly cleaning of cotton wool on the encapsulation machine.3.When cleaning the machine, it is necessary to use the canvas to protect the equipment and prevent the wool from falling into itI-4 Dete

35、ction improvingI-4 Detection improvingD M AIC1.Standardize the order of appearance inspections to avoid missing certain items.2.Buy the film card to increase detection.3.Conduct training and assessment the visual inspect for operator and FQA.I-4 Detection improvingI-4 Detection improvingD M AICPart

36、NoTMOV seriesPart NameTMOV seriesSpecifications:Reference visual standardOperator 1Zhang RuixiaOperator 2Liu JianxueOperator 3Deng ChaolianOperator 4Lu ChunlanTrials2 timesMSA-3A test after trainingD M AIC4 43 32 21 11 10 00 09 98 89 96 69 94 49 92 29 90 08 88 88 86 6A Ap pp pr ra ai is se er rP Pe

37、er rc ce en nt t9 95 5. .0 0% C CI IP Pe er rc ce en nt t4 43 32 21 11 10 00 09 98 89 96 69 94 49 92 29 90 08 88 88 86 6A Ap pp pr ra ai is se er rP Pe er rc ce en nt t9 95 5. .0 0% C CI IP Pe er rc ce en nt tD Da at te e o of f s st tu ud dy y: : R Re ep po or rt te ed d b by y: : N Na amme e o of

38、f p pr ro od du uc ct t: : MMi is sc c: : A As ss se es ss smme en nt t A Ag gr re ee emme en nt tWWi it th hi in n A Ap pp pr ra ai is se er rs sA Ap pp pr ra ai is se er r v vs s S St ta an nd da ar rd dEach Appraiser vs Standard Assessment AgreementAppraiser # Inspected # Matched Percent 95% CI1

39、60 58 96.67 (88.47, 99.59)2 60 57 95.00 (86.08, 98.96)3 60 57 95.00 (86.08, 98.96)4 60 57 95.00 (86.08, 98.96)# Matched: Appraisers assessment across trials agrees with the known standard.Assessment DisagreementAppraiser # OK / NG Percent # NG / OK Percent # Mixed Percent1 0 0.00 2 7.41 0 0.002 0 0.

40、00 1 3.70 2 3.333 0 0.00 2 7.41 1 1.674 0 0.00 2 7.41 1 1.67# OK / NG: Assessments across trials = OK / standard = NG.# NG / OK: Assessments across trials = NG / standard = OK.# Mixed: Assessments across trials are not identical.Fleiss Kappa StatisticsAppraiser Response Kappa SE Kappa Z P(vs 0)1 NG

41、0.932127 0.0912871 10.2109 0.0000 OK 0.932127 0.0912871 10.2109 0.00002 NG 0.931952 0.0912871 10.2090 0.0000 OK 0.931952 0.0912871 10.2090 0.00003 NG 0.914912 0.0912871 10.0224 0.0000 OK 0.914912 0.0912871 10.0224 0.00004 NG 0.914912 0.0912871 10.0224 0.0000 OK 0.914912 0.0912871 10.0224 0.0000I-4 D

42、etection improvingI-4 Detection improvingD M AIC决定测量系统Kappa 值有效性错误率错误警报率评价人可接受的条件大于等于0.7580%010%Zhang Ruixia0.93296.6707.41%Liu Jianxue0.9319503.7%Deng Chaolian0.919507.41%Lu Chunlan0.919507.4%3A conclusion:All operator are PASS for the 3A test after trainingI-4 Detection improvingI-4 Detection impr

43、ovingD M AICC-1 Update relevant documents C-2 Tendency chart of rejectedC-3 Result 持续 改善CMAIDC C阶段工作目录阶段工作目录D M AICC-1 C-1 文件更新标准化和培训文件更新标准化和培训序号序号文件名称文件名称编号编号关键改善内容关键改善内容1TMOV/iTMOV(14&20mm)PFMEA STE-811-004杂物风险识别2TMOViTMOV制程控制计划STQ-502-007杂物控制3TMOV三合一组装操作作业标准书STP-709-110切刀参数优化4TMOV(14-20mm) and ZA

44、 LA Series干式封裝作业标准书STP-709-112清粉，清机要求5TMOViTMOV1420MM目检作业标准书STP-709-115检验顺序，方法6清粉&清机记录表N/A定期清粉记录D M AICC-5C-5 Tendency chart ofTendency chart of surface surface contamination defect ratecontamination defect rate0.00%0.10%0.20%0.30%0.40%0.50%0.60%2017年12月2018年1月2018年2月2018年3月2018年4月2018年5月2018年6月2018

45、年7月2018年8月2018年9月2018年10月图表标题D M AICC-5C-5 Tendency chart of FQA Tendency chart of FQA rejectedrejected3123210100012341月2月3月4月5月6月7月8月9月10月Rejected lotC-1C-1 项目成果项目成果D M AICBaselineScrapTargetActualReduced by 35%Reduced by 35%SoSo far Octoberfar OctoberCurrent situationCurrent situation2017 data2017 dataBaselineRejected lots:23Rejected lots:15Rejected lots:13Thanks！