降低喷漆治具成本DMAIC

1•TeamIntroduction•Opportunity/BusinessCase/ProjectScope•TargetSettingAndSchedule•ProjectImplementation•Accomplishments/Results•TeamMembers’OfContactInformationTableofContent2•TeamIntroduction•Opportunity/BusinessCase/ProjectScope---Background---TheIntroductionOfPaintingProcess---ProjectScopeTableofContent3Industrialpollutiondamagesourenvironmentsignificantly.Background4GreenhouseeffectIcebergsaredisappearing.Penguinsarelookingforhome.“Iwanttogohome!”Daddy,whereisourhome?”“Idon’tknow”.Background5Ourcommitmenttosupportingenvironmentalprotectionofair,water,land,wasteandnaturalresourcesis,andwillremain,apriorityforthiscompany.EnvironmentalPolicyReducethepaintswasteandmaterialwasteBackground6TheintroductionofpaintingprocessDuringproduction：sprayinggunsprayAfterproduction:disassemblyproductsandrecyclefixtureCausepaintswastePreparation:Assemblyofrawpartstofixtureraw-partPaintfixturefinishedpartsPaintwasteusedfixtureOutputInput7AccordingtoenvironmentalimpactRPNevaluation,paintingfactoryconcludetoimprove:ProjectScope8•TeamIntroduction•Opportunity/BusinessCase/ProjectScope•TargetSettingAndSchedule•ProjectImplementation•Accomplishments/Results•TeamMembers’ContactInformationTableofContent91.Reducetheemissionofpaintsby20%2.Improvefixturerecycletimesby50%BeforeAfterAimingforsavingofpaintusageofthegapbetweenthetwoparts.Increasefixturerecycleperiodfrom2timesto3times150mm30mm30mm/150mm=20%TargetSettingImprovementAfter3XBefore2X10planactual08-Aug08-Oct08-Nov08-Dec09-Jan09-FebItemScopeStatusOverviewRootCauseanalysisSolutionDatacollectionEfficiencyStandardizationPlanSchedule08-Sep11G-ray(RimBlackberry-8000)Nicole(SonyEricssonK530i)Jie(SonyEricssonK630c)Aalto(NokiaN95)Meteor(RimBlackberry-9000)08-Oct08-Nov08-Dec09-Jan09-FebplanactualProjectSchedule08-SepProjectname12•TeamIntroduction•Opportunity/BusinessCase/ProjectScope•TargetSettingAndSchedule•ProjectImplementation---ReducePaintsWaste---FixtureRecycleTimesTableofContent13PaintsWasteManMethodEnvironmentMaterialMachineNotfollowSOPInsufficienttrainingchangepaintsmixingratioWrongfixturedesignParameterisnotcorrectAirpipedropoffColorunstableRawpartscleanlinessCleanroomcleanlinessBoothpressuretoohighBoothTemperaturetoohighBoothHumidity(40%~70%)1.1RootCauseAnalysisSpraypressuretoohighPaintingDirectionFixedFixturecleanlinessControlledWithoutcontrol1.ReducePaintsWaste141.2StatusOverview1.ReducePaintsWasteThefixedsprayinggunleadtopaintswastebetweentwospindlesSprayGunVideo=FixPaintingSprayGunCausePaintsWasteGap151.3SolutionRobotSpayPainting1.ReducePaintsWasteVideoofPaintingrobotEachsprayguntrackasinglespindleandspray,whichwillsavepaintbetweentwoparts.161.4DataCollectionPartsQ’ty(PCs)BeforeImprovement(g/pcs)AfterImprovement(g/pcs)Improvement(Save)%TotalSave(g)PAINTSTHINNERPAINTSTHINNERPAINTSTHINNERPAINTSTHINNERR/H2445451.621.781.2961.42420%20%79219.587042.5B/D2094921.621.781.2961.42420%20%67832.274531.6Capbottom2124330.810.890.6480.7220%19%34408.836108.2Total666470//////181460197682Paintssave20%PaintsreduceinSep.TaketheGAMMA-RAYasanexample1.ReducePaintsWaste171.ReducePaintsWasteGAMMA-RAYR/HB/D&BOTTOM20%GAMMA-RAYR/HGAMMA-RAYB/DGAMMA-RAYBOTTOM1.4DataCollection1.621.301.781.421.621.301.781.420.810.650.890.720.00.20.40.60.81.01.21.41.61.82.02.2PAINTSTHINNERPAINTSTHINNERPAINTSTHINNERFixedgunRobotPaintsreduceinSep.unit:g/pcs181.ReducePaintsWaste1995.86%93.90%95.66%95.80%93.80%95.68%B/DR/HCapBottomRobotFixedgunYieldratecomparisonbetweenrobotandfixedgun1.5QualityConfirmationGAMMA-RAYrobotpaintingyieldrateinSepvsfixedpaintinginAug.1.ReducePaintsWaste201.ReducePaintsWasteContinuousImprovementAndUpdatingBOMUpdatingBOM:Paints:from1.62g/pcsto1.296g/pcsThinner:from1.78g/pcsto1.424g/pcs21Statisticallywereducedpaintswastewithrobotsprayguntoreachourtarget,whilemaintaininggoodproductqualityatthesametime.Nextwewillintroducehowtoimprovethefixturerecycletimes.1.ReducePaintsWaste222.1StatusOverview2.FixtureRecycleTimesFixtureQuantity(A)94021pcsAssembledQuantity(perfixture)(B)26pcsPaintedQuantity(C)4889092pcsRecycleTimes(D)A*BCD==2Aug-2008G-ray’sData23MachineManMethodsEnvironmentMaterialInsufficientRecycleTimesTheamountoffixtureexhaustisbigUnitfixtureproductioncapacityislowerLessfixtureprojectsThefixturemachineiswellcontrolledFixturesurfaceisdirtyStorageenvironmentisdirtyFixturesupplierqualitycontrolisnotwellWithoutthedeclareofreducingthecostThelowerconsciousofreducingfixturecostFitsituationisnotwellOperationmethodnotwelltoknowFixturedesignisun-suitableHardtoassemblethefixtureThefixturefeestakeabout70%FixtureWasteBelackofeducation2.2RootCauseAnalysis2.FixtureRecycleTimesControlledWithoutControl242.3Solution2.FixtureRecycleTimes★Testfixturemaximumrecycletimes★Fixtures'reworkDecreasefixtureusagequantityEliminationofexhaustemissionIncreasefixturecycletimes？？？252.3.1TestTheMaximumRecycleTimesOfFixtures2.FixtureRecycleTimes1.3G-rayVolumeKeyBottomCoverTestInSep.2008Scrap%QualitycontrastTimesDefectParticleFiberCoveringPaintpeelOrangepeelGreasePoorCoverageTotal2th1.90.60.20.200.10.13.13th1.90.70.10.20.10.10.13.24th1.8