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“AGuideforAssessingthe“AGuideforAssessingthePerformanceofYourPerformanceofYourManufacturingOperation”ManufacturingOperation”WrittenBy:JoeBelmonteCooksonElectronicsProcessTechnology2002EM/SMEChairSummarySummary‹Productivity&QualityEfficiency‹WhatQuestionstoAsk‹ManufacturingSystem‹SampleAssessmentQuestions¾No“highmargin”productstoabsorbinefficientprocessesandpoorquality.¾Evenseeminglysmallimprovementsinqualityandcycletimecanproduceadramaticincreaseinrevenueandtheresultingprofits.¾ElectronicIndustry’scontinuingdemandfor“Better,LessExpensive”and“FasterTimetoMarket”products.¾Intenseworld-widecompetitionintheelectronicmanufacturingindustry.Productivity&QualityEfficiencyProductivity&QualityEfficiencyWhatQuestionstoAskWhatQuestionstoAsk9Whatarethemostcriticalelementsofanelectronicmanufacturingoperationthatmustbeevaluatedandmeasuredtoinsureitisperformingatanoptimumlevel?9Whatisthestandardforevaluatinghowwellmymanufacturingoperationisperforming?9Howcanoneevaluatewhatimprovementsshouldbeimplementedtoprovidethelargestpossiblereturn?WhatQuestionstoAskWhatQuestionstoAsk(continued)(continued)9Howdoesoneusethisinformationinthecreationofacontinuousimprovementprogram?9Howdoweknowiftheimprovementsweimplementareeffectiveandachievethepredictedresults?9Whatdowedotomovetothenextlevelofmanufacturingoperation’sperformance?ManufacturingSystemManufacturingSystem‹Evaluatethemanufacturingoperationasa“System.”‹Thecollectiveplans,activities,andeventsthatareprovidedtoensurethatproducts,processes,andserviceswillsatisfy,giventhecustomerrequirements.‹ManufacturingSystemAssessment(MSA)Evaluateallthesystems,procedures,documentation,organization,training,etc.thatdetermineandmanagethedevelopment,control,monitoring,andimprovementprogramofamanufacturingprocess.SampleSampleAssessmentAssessmentQuestionsQuestions‰DoallofyourProcessEngineersknowhowtorunalloftheprocessequipment?Wehaveexperiencedmanufacturingoperationsthathaveengineersresponsibleforequipmentandentireprocesslinesthattheyhavenotbeentrainedtooperate.Theycannotunderstand,letalonecorrect,basicproblemsiftheyhavenotbeentrainedtooperatetheequipment.Thisislikesendingasoldierintobattlewithoutaweapon,nomatterhowhardshe/hefightsorhowhardshe/heworks,she/hewilllosethebattle.SampleAssessmentQuestionsSampleAssessmentQuestions(continued)(continued)‰DoyouhaveawellthoughtoutSPCprogramandusethedataeffectively?ThebenefitofaneffectiveSPCprogramistostopdefectsfromhappeningasopposedtofindingdefectsthathavebeencreated.SPCisonetoolina“Proactive-ManufacturingEnvironment.”Findingdefectsaftertheyhappenisa“Reactive-ManufacturingEnvironment.”SampleAssessmentQuestionsSampleAssessmentQuestions(continued)(continued)‰Doyouhaveacontinuousimprovementplan?Themanufacturingorganizationmustbecontinuallyevaluatingitsperformancedatatodriveimprovement.Managementmustbecommitted,involvedandsupportivetothecontinuousimprovementprogram.Definitivequantifiablegoalsmustbedeterminedandmonitored.SampleAssessmentQuestionsSampleAssessmentQuestions(continued)(continued)‰Dotheprocessengineersknowthedifferencebetweenspecialcauseandcommoncauseprocessvariation?Commoncausevariationisanormalunidentifiableprocessvariation.Itisexpectedandwithinspecificationsoitdoesnotneedtobefixed.Specialcausevariationisaone-timeidentifiableprocessvariation.Adjustmentstoaprocessshouldneverbemadeforspecialcausevariation.SampleAssessmentQuestionsSampleAssessmentQuestions(continued)(continued)‰Dotheprocessengineersunderstandthebasicsofdesignformanufacturability(DFM)andnegotiateDFMissueswithcustomers?Theymustbeabletoworkwithbothinternalandexternalcustomerstooptimizetheproductdesign.SampleAssessmentQuestionsSampleAssessmentQuestions(continued)(continued)‰Dotheprocessengineersunderstandandapplysimpledesignofexperiment(DOE)conceptsandknowhowtouseMinitaborsimilarsoftwaretodoanalysisoftheDOEdata?DesignofExperiment(DOE)isapowerfultoolinoptimizingamanufacturingprocess.Itistheonlymethodavailabletoidentifyandquantifycriticaloperatingparameters.SampleAssessmentQuestionsSampleAssessmentQuestions(continued)(continued)‰Dotheprocessengineersknow“rootcause”analysisandhowtosolveproblemssystematicallywithformalanalyticalproblem-solvingtechniques?Eventhemostcomplexmanufacturingproblemscanbesolvedusingsystematic,analyticalproblem-solvingmethods.Avoidsolvingthesameproblemseveryday!!!SampleAssessmentQuestionsSampleAssessmentQuestions(continued)(continued)‰Doyouknowyouraverageprocessuptime?‰Doyouknowyouraveragelineunscheduleddowntime?‰Doyouknowyouraveragelineefficiency?‰Doyouknowyourinventoryturnsperyear?Allofthesemeasurementsarecriticalinunderstandingthe“health”ofaManufacturingSystem.SampleAssessmentQuestionsSampleAssessmentQuestions(continued)(continued)‰Doyourengineershaveadisciplinedandprovenstrategytomaximizethroughput?Therearetwowaystoincreaseprocesscapacity:Oneistoacquiremoreresources(people,equipment,building,etc.)Thesecondistoproducemorewithwhatyoualreadyhave.Inadditiontoreducingprocessdefects,theprocessengineersshouldbefocusedonproducingmorewithwhattheyhave.SampleAssessmentQuestions