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NOV-23-2000Page16SIGMABBProjectFDDDepartmentNOV-23-2000Page2主要内容6–SigmaProject登录书6–SigmaProject步骤书Measure-PhaseAnalyze-PhaseImprove-PhaseControl-Phase6–SigmaProject结束报告书NOV-23-2000Page3HeadCarriage(NutMiss)SpindleMotorAss'yCarriage-UPAss'yHGASide0PCB-MainAss'y(FDD)BezelAss'yOthers881468042247691174371013152381213733.730.818.36.73.92.04.633.764.582.889.593.395.4100.00100000200000020406080100DefectCountPercentCum%PercentCountParetoChartforMaterialDesDefine–Project选定事由D废弃金额最大原材料不良废弃分析（10/1~10/31）NOV-23-2000Page46SIGMAProject登录书部门长推进事务局财会TEAM长ChampionBond涂抹工程，Nut熔着工程，CarrigeUpper组立工程。Leader杨进部门长邓常松PROJECTDMAIC周建良推进日程9/3~9/209/21~9/3010/3~10/3011/1~12/112/1~12/30贺志才NUT原材料尺寸不良；Nut原材料改善；问题点CarriageLowerNut组立Hole设计问题；CarriageLowerNutHole设计变更；(现水准)富钢NUT组立工程压入不良；富钢相关作业者作业方法，组立设备改善MainLineCarriageUpper组立不良。MainLine作业者教育。效果金额单品在工材料费基准材料费：(5710-1000)*70000*(6.5+1)*27*12/10000000=801,171RMB向上率成果指标活动前刘晓星PROJECT活动期间2000.10.3.~2001.1.31.活动方向朴夏律金英浩工程不良率活动后PROJECT名关联Process指导BB活动MemberCarriageLowerNUT脱落不良改善朴夏律Sigma水准5710PPM82.50%4.03δ1000PPM4.59δ现水准PROJECT效果NOV-23-2000Page56SIGMAProject步骤书■PROJECT选定事由■现象确认(问题中心)工程不良率高，关联原材料浪费严重，*WHAT(对象)影响工程品质及生产性，且不良原因集中Nut&CarriageLower*WHERE(关联工程)Nut熔着工程、S1组立工程*HOW(关联指标)Secew组立不可■现象确认2(4M侧面)■效果S*给部门带来的影响*MANNut熔着工程人员，降低产品返修率，提高工程品质及生产性S1组立工程人员O*MACHINENut熔着机S1组立DriveL*给顾客带来的影响*MATERIALNut&CarriageLower提高产品信赖性，降低User不良率，V达到客户满足的要求。*METHODNut熔着工程作业方法教育S1组立工程作业方法教育E■最高目标GAP分析■解决方案(对策)Sensor原材料弹性增强；■为测定分析的适用方法关联Jig重新调整；相关作业者作业方法教育；Nut熔着JIGGaugeR&R评价Line别工程不良统计比较。DriverTorque管理ImplementChartNOV-23-2000Page6ProcessMappingNUTpress&drillN-作业者N-设备偏差C-DriveTorqueC-S1组立JigN-作业者涂抹量N-Bond涂抹均匀性C-Bond浇口大小C-Bond干燥时间C-Bond性能N-作业者Nut安放C-压入Jig定位C-压入JigAirpressC-压入Jig冲头行程C-工作台异物S-压入Jig的润滑N-作业者S-设备预热S-模具温度C-模具尺寸C-部品结构C-成型毛刺C-材料性质Nut&CarriageLowerAssemblyBond涂抹工程S1AssemblyS1&CarriageLower组立Nut外围Bond涂抹Nut&CarriageLower组立CarriageLower成型C/L注塑成型NutPressNutDrillN-作业者N-设备震动C-模具精度C-模具保养C-DrillMacheine精度C-定位精度C-材料性质S-设备润滑MNOV-23-2000Page7作业不标准外观检查不良NUT模具不良Bond涂抹不均或量少Nut压入Jig不良Nut压入JigAir不良Nut外径尺寸不良Nut同心度不良Nutdrill不良C/L内径尺寸不良Bond粘度不良DriveTorque过大目视检查Nut测试不良模具别偏差Bond保管处温度高PersonnelMachinesMaterialsMethodsMeasurementsEnvironmentNut脱落不良分析Cause-and–EffectDiagramNut脱落不良MMeasurementsMaterialsMenMethodsMachinesEnvironmentNOV-23-2000Page8XYMatrixM12345678910OutputVariables(Y's)Nut&C/L配合状况Bond粘着力Nut压入状况Nut脱落程度OutputRanking98710InputVariables(X's)AssociationTableRank%Rank1Nut外径尺寸9191025212.47%2NutScrew同心度111101246.14%3NutScrew破损11191145.64%4C/L内径尺寸8181023611.68%5C/Lhole外型619820510.14%6Bond涂布量210191959.65%7Bond粘性19191788.81%8Bond涂布均匀度17171427.03%9压入JigAirPress11991708.41%10压入Jig定位21871527.52%11DriveQurque11181045.15%12组立作业方法312101497.37%13141516ViewResultsDeleteInstructionsDEMONOV-23-2000Page9CharacteristicSelectionMatrixResults0%10%20%30%40%50%60%70%80%90%100%Nut外径尺寸NutScrew同心度NutScrew破损C/L内径尺寸C/Lhole外型Bond涂布量Bond粘性Bond涂布均匀度压入JigAirPress压入Jig定位DriveQurque组立作业方法InputCharacteristicCharacteristicImportance(%)M【续上】改善必要!!!NOV-23-2000Page10ProcessFMEAMPotentialFailureModesandEffectsAnalysisProcessName:Track00AlignmentProcessResponsibility:工程技术队AffectedProduct(s):3.5''DoubleHighDensityFDDPFMEAKeyDate:1999年12月20#ProcessFunction(Step)PotentialFailureModes(processdefects)PotentialFailureEffects(Y's)SEVClasPotentialCausesofFailure(X's)OCCCurrentProcessControlsDETRPNRecommendActions1NutPress&Drill模具凹模尺寸不良Nut外径尺寸不良9模具不良6模具制造管理5270NutDrill不良NutScrew不良10DrillMachine不良2Drill设备控制480NutDrill定位不良Nut同心度不良10定位Jig不良3Drill定位Jig精度390材料不良Nut尺寸变形9材料不良3QC抽检5135模具磨损Nut尺寸不良10模具不良5定期保养42002CarriageLower模具凸模尺寸不良C/L尺寸不良10模具不良5模具制造管理4200注塑条件不良C/L尺寸变化8设备管理不良3标准操作者管理372模具型芯尺寸不良Nut定位不良10模具不良5模具制造管理5250Resin不良C/L尺寸变化7原材料不良3QC抽检242C/L内异物C/L压入变形85S管理不足4生产管理396NOV-23-2000Page11【续上】M#ProcessFunction(Step)PotentialFailureModes(processdefects)PotentialFailureEffects(Y's)SEVClaPotentialCausesofFailure(X's)OCCCurrentProcessControlsDETRPNRecommendActions3Nut&C/LAssemblyNut安放不好Nut压入不良8作业者疏忽4外观检查100%目测396压入JigAirPress未管理压力不足8设备管理不良6无管理7336压入Jig定位不良C/L破损8设备不良5设备定期管理4160压入Jig冲头BendNut压入变形9设备不良3设备定期管理4108压入Jig冲头行程不足Nut未压紧9设备不良4设备定期管理62164Bond涂布工程涂布不均匀Nut粘着力不强7作业方法无标准化，作业者品质意识差6外观检查100%目测8336涂布量不足Nut粘着力不强7作业方法无标准化，作业者品质意识差5外观检查100%目测7245Bond涂布器浇口不良Bond涂量不足7作业工具无标准化5无管理8280Bond干燥状况Nut粘着力不强8干燥环境差4自动干燥396Bond粘性Nut粘着力不强9原材料不良3无管理8216点滴方法Nut粘着力不强5作业方法无标准化，作业者品质意识差5无管理71755S1AssemblyDriveTorque不良Nut受力大6Torque管理不足31Time/2Shift点检6108作业者方法Nut受力方向不良5作业方法无标准化，作业者品质意识差4100%全检6120NOV-23-2000Page12AttributeGaugeR&REffectivenessSCORINGREPORTDATE:2000-11-15AttributeLegend5(usedincomputations)NAME:AlliedEmployee1passPRODUCT:SFD-321B/***Alloperators2failBUSINESS:agreewithinandAllOperatorsbetweeneachagreewithOtherstandardKnownPopulationY/NY/NSample#AttributeTry#1Try#2Try#1Try#2Try#1Try#2AgreeAgree1passpasspasspasspasspasspassYY2passpasspasspasspasspasspassYY3passpasspasspasspasspasspassYY4failfailfailfailfailfailfailYY5passpasspasspasspasspasspassYY6passpasspasspasspasspasspassYY7failfailfailfailfailfailfailYY8passpasspasspasspasspasspassYY9failfailfailfailfailfailfailYY10failfailfailfailfailfailfai