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上海交通大学硕士学位论文SGSRoHS测试流程优化及成本控制研究姓名：罗爱军申请学位级别：硕士专业：工商管理指导教师：张兴福20090524SGSRoHSRoHS200671SGSSGSSGSRoHSSGSRoHSRoHSSGSRoHSRoHSSTUDYOFSGSROHSTESTPROCESSOPTIMIZATIONANDCOSTCONTROLABSTRACTWiththedevelopmentofSGS’sbusinessinchinaandthetakingeffectofRoHSdirectiveofEUonJuly1st2006,thetestingneedsofhazardoussubstancesinelectricalandelectronicequipmentincreasedrapidly.AndithascsusedgreatstressandgreatchallengeforSGS.Forexample,ithadcausedsomeproblemsinsomelabs,suchasincreasedcost,unreasonableschedulearrangement,risingrateofreportdelay,unreasonablesystemoftelephonecommunicationandincreasingcustomercomplaintsetc..Theseproblemshadbeensolvedpartiallybyincreasingemployeesandovertime,butthecostremainshigh.ThereforeprocessimprovementisurgentforSGSRoHS.Inthisarticle,weproposedboththeshort-temandlong-temsolutionsfortheseproblems.Forshort-tem,cutdownthecostofschedulearrangementbydatamodelofLinearProgram,improveserviceefficiencybyinternalinformationcentralization,shortentestingcycletimebyonepieceflowofLeanproductiontheoryandtool.Wehaveachievedcertaineffectbythesemeasures.Butprocessoptimizationisacontinuousprocess.Forthelong-tem,weputforwardsomeotheroptimizationmeasuresbasedontheleanthinkingandotheroptimizationtheories.ThesemeasuresincludeoptimizingRoHSvalueflow,settingupcallcenter,usingsystemoflogisticscodingandsamplenumbering,integratingfrontdeskresourceofcustomerreception,establishingcoordinationmechanism.Intheend,futruredirectionsforSGSRoHStestprocessoptimizationandcostcontrolwasbroughtforward.KEYWORDS:RoHSprocessoptimization,study20090418MBASGSRoHS1SGS2008302007RoHS80%RoHS2000RoHSRoHSRoHSRoHSRoHSRoHSRoHSSGSRoHSRoHSRoHSMBASGSRoHS21SGSRoHS1.1SGSSGSSocieteGeneraledeSurveillanceS.A.1887,251256400001421.2SGSSGSSGS23SGSSGSSGSComprehensiveImportSuper-visionScheme,CISSSGSSGS,SGSHS,SGSCleanReportofFinding,CRF,,SGS1,MBASGSRoHS32SGS,.3CISS,SGS,,,4,,SGSS/DSGS1.3SGS1.3.1SGS1991SGS-CSTC24600020SGS200830500SGSSGSSGSSGSSGSSGSSGS1.3.2101MBASGSRoHS42345(ISO9001,ISO14001,TS16949,IECQ,ISO2200,ISO27001,TAPA,SA8000,OHSAS18001,TL9000,HACCP,FSC/COC,ISO13485)678SGS9101.4RoHS1.4.1RoHS2006,6,,6,,4-6MBASGSRoHS5,,,,,WEEERoHS[1]20031232002/95/ECRoHS(TheRestrictionoftheuseofCertainHazardousSubstancesinElectricalandElectronicEquipment)(885)[2]WEEEWEEE20031272002/96/EC(wasteelectricalandelectronicequipment)2005813[3]20048142005313200671WEEERoHS6(PBBs)(PBDEs)6()6(Pb)(Hg)(Cr6+)(PBBS)(PBDEs)0.1%(Cd)0.01%RoHS[4]1.4.2RoHS2006228200731[5]1.4.3SGSRoHSSGS24RoHS1000RoHSRoHSRoHSSGSRoHSRoHSMBASGSRoHS6RoHSXRF()RoHSSGSRoHS2002/95/ECRoHSRoHSSGSSGSRoHSRoHS100%SGSRoHS2008SGSRoHS80RoHS2000SGSSGSRoHSRoHS1.4.4SGSRoHSSGS20081580IBMTCLRoHS1.4.5RoHSRoHSCNAS()CQC()RoHS100RoHSSGSBVQIITSTUVRoHS30%BVQIMBASGSRoHS7RoHS90%SGS80%BVQIITS5%RoHSRoHSSGSITSRoHS[6]MBASGSRoHS82RoHSSGSRoHSITSBV2.1SGSRoHSSGSRoHSSGSRoHS:1SGSRoHSSGS2,364605OTIS(SGS)EXCEL.6EXCELOTIS(SGS)7SGS8MBASGSRoHS9OTIS,,,9EXCEL10601112,,,601314DDWordJ6015,J16,,,,1718MBASGSRoHS101920211EPA3060ISO3613IECDIN5314EN42022PBBsPBDEs55123GC-MSPBBsPBDEs1000PPm1524GC-MS-PBBsPBDEsGC-MS-GC-MS-6025ICP6026Hg60276029UV306Cr3060316032WordMBASGSRoHS1160333435363121373839OTISOTISordertraceSGSEXCEL4041OTIS6042OTISordertraceYes244344451EMSRoHSSGSSGSMBASGSRoHS122.2SGSRoHSSGS2.2.1SGSRoHSSGS12008161200816Table1TheDelayRateandQuantityofChemicalLabfromJan.toJun.of2008200812008120081200812008120081()1756819347245682756823897265614()2939359647854898457842355()7399391539293924132822416.73%18.59%19.48%17.77%19.16%15.94%54.21%4.85%6.26%10.66%10.10%10.62%457510%RoHS2.2.2RoHS2.2.3RoHSRoHSSGSMBASGSRoHS136sigma(1)SGS,(2)SGS,,.SGS8(3)SGSSGS(4)SGSSGS(5)RoHSSGS(6)SGSSGSITS(7)SGSITSRoHSSGS2.2.4SGSCSI(CustomerSatisfactionIndex),,,,SGS[7]MBASGSRoHS14SGS1SGSContrastofSatisfactionIndexonChemicalTestingbetweenSGSandCompetitorsSGSSGS80.8%20%SGSRoHS2.2.5SGSMBASGSRoHS15SGS2SGS()ContrastofSatisfactiononChemicalTestingbetweenSGSandCompetitorsaboutServiceEffectSGSSGS80.8%20%2SGS/2.2.6,,SGSMBASGSRoHS16SGS3FIGURE3AnalysisofUsingSGSChemicalTestingRateUnceasingly3SGS20%3SGS/ITSSGS2.2.7SGSMBASGSRoHS17SGS4SGSFIGURE4RiskAnalysisandPotentialOpportunitiesonSGSChemicalTesting4SGS//2.2.8SWOTSWOT2080SWOTStrengthWeaknessOpportunityThreatSWOTSWOTMBASGSRoHS18SGSSWOTSGS5-FIGURE5MatrixAnalysisPictureofServiceAssessmentonChemicalTesting5SGSSGS2.3SGSRoHSSGSRoHS2.3.1SGS2.3.27MBASGSRoHS192.3.32.3.42.3.5OTISEXCEL,2.3.62.3.72.3.82.3.92.3.10SGS,,MBASGSRoHS20RoHSRoHSMBASGSRoHS2133.13.1.13.1.21MBASGSRoHS22x1,x2,,xn02x1,x2,…,xn03c1,c2,,cn4b1,b2,,bn56a11,a12,…,a1n[8]MBASGSRoHS233.23.2.1LeanProductionLPIMVPJITJustInTime,3.2.2LeanThinkingLeanTechniques1Value2ValueStreamMBASGSRoHS243Flow“”“”4Pull“”JITJust-in-timeOne-PieceFlowJIT5PerfectionJamesP.Womack“”“”33.2.3-JITJITPDCA3.3MBASGSRoHS253.43.4.13.4.2MBASGSRoHS266FIGURE6ValueFlowSign3.4.33.4.3.13.4.3.2(1)(2)(3)C/TC/OEPEFIFOMBASGSRoHS27(4)3.4.3.3,(1)(2)(3)(4)(5)(6)(7)3.4.3.4,7123,4567MBASGSRoHS28MBASGSRoHS294RoHS4.130%60%30%60%10%SGSSGSRoHS6244.1.11,900-1200100-530MBASGSRoHS302Table2ShiftInformation19001800120013000002110019001300140040307031200