精益生产在闪存芯片封装测试生产线优化项目中的运用

上海交通大学硕士学位论文精益生产在闪存芯片封装测试生产线优化项目中的运用姓名：阮凯庆申请学位级别：硕士专业：控制工程指导教师：汪小帆;林丽华20080608VVIVIIAPPLICATIONOFLEANMANUFACTURINGTOFLASHASSEMBLYANDTESTPRODUCTIONLINEOPTIMIZATIONABSTRACTInordertoenlargeitsmarketandsalesinAsiaareacontinuously,AAAChinaCorp.introducesandimplementsLeanProduction,requiresitsProductionDept.toeliminatewasteandreduceproductioncost.Accordingtotheproductionstatusquoofflashdepartment,thepaperusesVSM(ValueStreamMapping)technologytoidentifywasteincurrentprocessactivities.Meanwhile,usethesixsigmatoolDMAIC(Define,Measure,Analyze,ImprovementandControl)tooptimizetheproductionline.Additionalqualitycontroltoolwasusedtoassessqualityimpactafterlineoptimization,suchasFMEAandSPCchart.ThepaperutilizeIEtheoryandleanmanufacturingtooltoplanandimplementasetofleanproject,mainlyfocuson3stationsinAssemblyline.Firstly,useworkmeasurementmethodtore-organizationthediebatchprocess,itsavetheoperatorheadcount,reducetheleadtimeandeliminatethewasterofsubstrateatutmost;Secondly,useprocessmap,measure/analyzecriticalthoughtmapandFEMAtooptimizeDAPMVIII(ProductionMaintenance)process,reduce1hrnon-valueadded,equivalentto0.05%;Lastly,useCauseandEffectiveMatrixandsixsigmabasictoolstooptimizeWireBondstation,maketheoutputlinearization,andimprovemachineutilizationby6%throughtheproject.Finally,wesummarizetheresult,draw“ToBe”valuestreammapping.Bymeansofleanmanufacturingimplementation,FlashdepartmentimprovetheLeadTimeby7.58%,ProductionCycleEfficiencyby7.65%,thesametimesave$2605Kcostin5years.LeanmanufacturingapplicationinFlashmanufacturingdepartmentisagoodbeginningofcontinuousimprovement,andsetasolidfundamentaltoboostleanthinkingtowholecompany.KEYWORDS:IndustryEngineering,LeanProduction,VSM,6SigmaIIIIV12345678910111213Fig.1-1TechnicalRoute14Fig.2-1AsampleofFlashUnit1516Fig.2-3ProductTestFlow171819Fig.2-4CustomerOrientationProcess20NetAvailableTime(Sec/Day)75600CustomerDemand1000000perweeksTaktTime(seconds)0.529Shifts2NameLeanType(hours)TotalC/T(seconds)ValueAdd(seconds)NVA(seconds)ShiftsTimelineInventory2DPTimelineActivity8.98100032040489602TimelineInventory2FOLTimelineActivity15.2200520547201458002TimelineInventory2EOLTimelineActivity21.3248400766801717202TimelineInventory2TPOTimelineActivity18842400648007776002TimelineInventory2FPOTimelineActivity25572400900004824002Table2-1AssemblyandTestLineWorkMeasurement21eprocesstim∑2223²²²²²²²²²²²24252627uuuu28ØØØز²²²2930313233(Flash)2.730(SRAM)6.780.538269/1.74126248245.134/12241065.81206.867.05834(Flash)2.730(SRAM)6.780.53826910.402/1.74126248245.1348.968/122410606.6810.47.0588.9685.805.81206.867.05835Fig.3-2DieBatchFlow(ToBe)ØØØØ36FFFFFFig.3-3DefineCriticalThoughtMap3738Fig3-5MeasurementCriticalThoughtMapØØFig.3-6MCUtilizationSPCControlChart0.800.850.900.951.00ProportionforMachineAvailability3691215182124273033SampleAvg=0.9137LCL=0.8294UCL=0.997939Fig.3-7ProcessTimeSPCControlChartMeasureMeasurementSystemUnitofMeasureConditionProductivity(CycleTime)PMRecordSheetHrNoexcursionduringPM,suchaspotentialpartsdamage.Delivery(Capacity)EquipmentIndicatorAU100%NoexcursionduringPM,suchaspotentialpartsdamage.Quality(Yield)Yield(EATSsystem)DPMNoothernoise,suchasSOPviolation.Fig.3-3MeasurementObjective,System,UnitofMeasure,ConditionTable051015CountforCycleTime3691215182124273033SampleAvg=7.97LCL=0.00UCL=16.4440Fig.3-8AnalyzeCriticalThoughtMapØØØØØ41ProcessStep/InputPotentialFailureModePotentialFailureEffectsSEVPotentialCausesOCCCurrentControlsDETRPN1MachineinsidecleaningFMondiemissingwireonthedie10SOP3emphasizetheSOP3902Parametersmatrixcheckwrongparametersettingdetectdie10SOP/parametermatrixdataissueorhavenotbeenupdated3emphasizetheSOPandtimelyupdatethematrix3903Pickupvisioncheckandcalibrationwrongpickuporplacementshiftmixdie/adhesiveondie10skillofcalibration3BKMsharingandeffectivetrainingandpractice/ERvalidation3904LubricationofY-Shuttley-shuttlemotorjamMCdownandleadtowaferjam10lackofexperience/non-effectivelubrication3BKMsharingandeffectivetrainingandpractice/ERvalidation3905Checkandcleanbondheaddiecrack/diemissing/dietilted/High/LowBLT/Incompletewetoutyieldloss10non-effectiveclean,andlackofskillonparameteradjustment/potentialdefectpartscouldnotbedetected5BKMsharingandeffectivetrainingandpractice/ERvalidation31506Lubricationofdieejectorejectjamyieldloss7lackofexperience/non-effectivelubrication7BKMsharingandeffectivetrainingandpractice/ERvalidation31477Checkandlubricationofindexerpush-outrollerIndexerjamandleadtosubstratejamyieldloss10non-effectiveclean,andlackofskillonparameteradjustment/potentialdefectpartscouldnotbedetected7BKMsharingandeffectivetrainingandpractice/ERvalidation32108IndexerteachandclampcheckIndexerjamandleadtosubstratejamyieldloss10non-effectiveclean,andlackofskillonparameteradjustment/potentialdefectpartscouldnotbedetected7BKMsharingandeffectivetrainingandpractice/ERvalidation53509FPDbearinganddrivebeltcheckdiecrack/diemissing/dietilted/High/LowBLT/Incompletewetoutyieldloss10non-effectiveclean,andlackofskillonparameteradjustment/potentialdefectpartscouldnotbedetected7BKMsharingandeffectivetra