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IE七大手法SMT案例防呆法1.此新機種Raptor量產初期,SMTBSide目檢工站發現SDConn空焊(浮高)與掉件不良,達0.78%,占總不良比重:22%,居不良首位2.此現象為物件性能受力問題,可考慮增加治具,采用防錯法,以提高SMT產品良率.背景介紹案例1改善后在BSideReflow前增加一個夾具(如圖),能彈性的支撑SDConn,防止焊點重熔時受重力等影響產生不良.彈片支撑CN23夾持PCB板邊不良率降到0.01%IE分析標准工具使用了防錯法案例1案例改善后狀況通過增加治具,因過BSideReflow導致的該不良從0.78%降到0.01%.產品品質得到客戶更好的認可改善后的效果-----增加治具防錯法案例1抽查法印刷機中速機泛用機預觀測次數35.0%80.0%55.0%20印刷機中速機泛用機743100327隨機抽測數次代入公式計算確定測試次數N=4(1-P)PS2案例1工作抽樣結果工作負荷20.4%67.2%84.4%0.0%20.0%40.0%60.0%80.0%100.0%印刷機中速機泛用機站別工作負荷較小案例11.此為游戲機電路板產品SMT線作業,作業員在作業時,效率低下.2.此問題分析人員工作比率,可考慮工作抽樣法,以提高人員的利用率.背景介紹Aside(10人)Bside(11人)NO工站人數NO工站人數1線長11線長12全技員12全技員13印刷13印刷14上料24上料25爐前目檢15爐前目檢16AOI16AOI17爐后比對17爐后比對18爐后目檢28爐后目檢3合計工站10人合計工站11人案例2對SMT線人員進行工作抽樣,確定人員工作比率,精簡人力,提高人員利用率.利用工作抽樣法評估﹕IE分析標准工具上料VVVVVVVVVVV11卸料VVVVVV6領料VV2機故處理V1途中V1私事VVV3空閒VVV3上料VVVVVVVVVVVVV13卸料VVVV4領料VV2機故處理V1途中VV2私事VV2空閒VVV3上料VVVVVVVVVVVVVV14卸料VV2領料VV2機故處理VV2途中VVVVV5私事0空閒VV2上料VVVVVVVVVVVVVVV15卸料V1領料VVV3機故處理VVVV4途中VV2私事VV2空閒VVVV4SMTA-Side上料員一合計合計工作比率：80.7%SMTB-Side上料員二時間項目8:559:059:159:259:359:459:5511:1510:0510:1510:2510:3510:3514:1513:4513:5514:0511:2511:3510:4510:5511:0510:4510:5511:0511:1511:2511:3513:4513:5514:0514:1514:2514:3514:2514:3514:4514:5516:1515:0515:1515:2515:3517:0517:158:4516:2516:3516:4516:5515:4515:5516:05時間項目8:458:559:059:159:259:359:459:5510:0510:1510:2514:4514:5515:0515:1515:2515:3515:4515:5516:0516:1516:2516:3516:4516:5517:0517:15時間項目8:509:009:109:209:309:409:5010:0010:1010:2010:3010:4010:5011:0011:1011:2011:3011:4013:4014:5015:0013:5014:0014:1014:2010:0016:3016:4016:5015:5016:0016:1016:2015:1015:209:209:309:409:50時間項目8:509:009:1010:1010:2010:3010:4010:5011:0011:1011:2011:3011:4013:4013:5014:0014:1014:2014:3014:4014:5015:0015:1016:3015:2015:3015:4015:50工作比率：92.6%SMTA-Side上料員二SMTB-Side上料員一16:4016:5017:0017:1016:0016:1016:20工作比率：77.8%工作比率：81.5%合計合計17:1017:0015:3015:4014:3014:40使用了工作抽樣表案例2案例改善后狀況對SMT線人員進行工作抽樣,確定人員工作比率,精簡人力,提高人員利用率.改善績效:人員精實:每線每班精實4人上料VVVVVVVVVVV11卸料VVVVVV6領料VV2機故處理V1途中V1私事VVV3空閒VVV3上料VVVVVVVVVVVVV13卸料VVVV4領料VV2機故處理V1途中VV2私事VV2空閒VVV3上料VVVVVVVVVVVVVV14卸料VV2領料VV2機故處理VV2途中VVVVV5私事0空閒VV2上料VVVVVVVVVVVVVVV15卸料V1領料VVV3機故處理VVVV4途中VV2私事VV2空閒VVVV4SMTA-Side上料員一合計合計工作比率：80.7%SMTB-Side上料員二時間項目8:559:059:159:259:359:459:5511:1510:0510:1510:2510:3510:3514:1513:4513:5514:0511:2511:3510:4510:5511:0510:4510:5511:0511:1511:2511:3513:4513:5514:0514:1514:2514:3514:2514:3514:4514:5516:1515:0515:1515:2515:3517:0517:158:4516:2516:3516:4516:5515:4515:5516:05時間項目8:458:559:059:159:259:359:459:5510:0510:1510:2514:4514:5515:0515:1515:2515:3515:4515:5516:0516:1516:2516:3516:4516:5517:0517:15時間項目8:509:009:109:209:309:409:5010:0010:1010:2010:3010:4010:5011:0011:1011:2011:3011:4013:4014:5015:0013:5014:0014:1014:2010:0016:3016:4016:5015:5016:0016:1016:2015:1015:209:209:309:409:50時間項目8:509:009:1010:1010:2010:3010:4010:5011:0011:1011:2011:3011:4013:4013:5014:0014:1014:2014:3014:4014:5015:0015:1016:3015:2015:3015:4015:50工作比率：92.6%SMTA-Side上料員二SMTB-Side上料員一16:4016:5017:0017:1016:0016:1016:20工作比率：77.8%工作比率：81.5%合計合計17:1017:0015:3015:4014:3014:40改善前的工具表----抽樣表.案例2