降低三星产品N46不良率蓝微品质部Blueway(蓝微电子有限公司)降低三星产品N46不良率Competitor(竞争对手)Company(公司水准)CustomerNeeds(顾客要求)1.产品要求零缺陷目标2.无重大品质隐患3.提高产品质量,推动品质竞争力.1.来料不良较多2.顽固性不良改善度不够.3.剧烈的竞争环境要求我们必须降低生产成本.1.同行业竞争激烈2.建立具备强有力的品质水准3.占有较大产品市场份额随着三星客户为公司重点战略客户,其产品要求甚高,对制程进行改善迫在眉睫,通过本次活动,旨在降低不良率,赢得高端客户对我司的信心,从而打出知名度,占有更多市场.项目背景DMAIC组长郭威品质部徐斌(经理)陈群(主任)品质部•改善方案评估•改善方案制定•改善因子分析•数据统计工程部方永智(主任)赖雪妹(主任)生产部生产部李新军(主任)指导陈安•改善方案实施IE部梁启能(主任)•文件标准化•改善效果跟进组织构成DMAIC8750070652805387166732594387000200004000060000800001000003月4月5月6月7月合计目标设定38700PPM品质现况改善目标下降7500PPM80%总不良率:38700PPM客户要求年终目标:7500PPMDMAIC客户要求改善KPI品质现况1300012000110001000085007500020004000600080001000012000140007月8月9月10月11月12月CountPercentC4Count9.84.94.3Cum%46.581.090.895.7100.04923641045245Percent46.534.4Other点胶不良元件焊接不良导线焊接不良导线长短不一120010008006004002000100806040200ParetoChartof制程不良品质现况分析52%48%制程不良率来料不良数DMAICCountPercentC1Count7.0Cum%45.783.693.0100.054845411284Percent45.737.99.3镍片划伤假性露铜过孔不通露铜不良120010008006004002000100806040200ParetoChartof来料不良来料不良制程不良来料占主要不良为露铜不良及过孔不通制程占主要不良为导线长短不一及导线焊接不良主要不良主要不良Y定义DMAIC镍片MOSICPTC电容电阻导线N46产品介绍Y定义DMAICB+铜箔边缘露铜。区分不良类别(Y值)不良图示来料不良露铜不良过孔不通Y定义DMAIC区分不良类别(Y值)不良图示制程不良导线长短不一导线焊接不良Y1:焊导线拉拔力1.0kgfY2:外观品质:(1)少锡(2)导线皮起皱标准为6.50-7.10mm改善方案导出DMAIC时间DefineMeasureAnalyzeImproveControl8月时间:8.1~8.24计划:课题导出目标设定现况调查时间:8.25~9.15计划:系统GR&R数据采集制程能力分析时间:9.16~10.15计划:原因分析因子筛选改善方向导出时间:10.16~11.30计划:改善案实施改善案效果确认时间:12.1~12.30计划:向后管理成果计算文件标准化已完成进行中12月9月10-11月ProcessMappingDMAICPCB打码过程输入输出CTQ印锡膏贴片炉前检查回流焊AOIPTC测试自动分板过程输入输出CTQ焊导线焊接检查点UV胶UV胶固化ATE测试终检PCB来料锡膏电阻/电容/镍片导线UV胶导通孔开路QC抽检铜箔到边不良导线长短不一导线焊接不良焊导线、ATE测试、终检定为CTQ工程点胶不良元件焊接不良元件贴装不良印刷不良打码不良PTC内阻不良分板不良制程能力分析MAICDSampleProportion109876543210.0750.0500.0250.000_P=0.0387UCL=0.04204LCL=0.03536Sample%Defective1086426543SummaryStats0.00PPMDef:38700LowerCI:37932UpperCI:39479ProcessZ:1.7660LowerCI:(using95.0%confidence)1.7568UpperCI:1.7752%Defective:3.87LowerCI:3.79UpperCI:3.95Target:SampleSize%Defective3000020000100007.55.02.50.010864203210Tar111111111BinomialProcessCapabilityAnalysisofC5PChartTestsperformedwithunequalsamplesizesCumulative%DefectiveRateofDefectivesDistof%Defective◆DPMO=38700ppm◆Z-level=1.76(查MINITAB表)GageR&RMAICD区分不良类别(Y值)测试项目测量工具GageR&R数据类型来料不良露铜不良外观放大镜计数型过孔不通自耗电ATE计量型制程不良导线长短不一尺寸二次元计量型导线焊接不良外观拉拔力放大镜拉力计计数型计量型StudyVar%StudyVarSourceStdDev(SD)(6*SD)(%SV)TotalGageR&R0.001000.00600.02Repeatability0.000870.00520.02Reproducibility0.000490.00290.01Operator0.000360.00210.01Operator*Sample0.000330.00200.01Part-To-Part4.2739225.6435100.00TotalVariation4.2739225.6435100.00NumberofDistinctCategories=6038GageR&RMAICD二次元测试系统分析520%PercentPart-to-PartReprodRepeatGageR&R100500%Contribution%StudyVarSampleRange0.0040.0020.000_R=0.001415UCL=0.003643LCL=012SampleMean1050__X=5.60UCL=5.60LCL=5.6012Sample109876543211050Operator211050SampleAverage109876543211050Operator12Gagename:Dateofstudy:Reportedby:Tolerance:Misc:ComponentsofVariationRChartbyOperatorXbarChartbyOperatorYbySampleYbyOperatorOperator*SampleInteractionGageR&R(ANOVA)forYGageR&RMAICD推力计测试系统分析PercentPart-to-PartReprodRepeatGageR&R100500%Contribution%StudyVarSampleRange1680_R=5.85UCL=15.06LCL=012SampleMean15010050__X=120.8UCL=126.7LCL=114.812C8C121109876543211098765432115010050C82115010050Gagename:Dateofstudy:Reportedby:Tolerance:Misc:ComponentsofVariationRChartbyC8XbarChartbyC8C2ByC1(C8)C2byC8GageR&R(Nested)forC2StudyVar%StudyVarSourceStdDev(SD)(6*SD)(%SV)TotalGageR&R3.554321.3269.19Repeatability3.554321.3269.19Reproducibility0.00000.0000.00Part-To-Part38.5030231.01899.58TotalVariation38.6667232.000100.00NumberofDistinctCategories=15520%GageR&RMAICDATE测试系统分析520%Gagename:Dateofstudy:Reportedby:Tolerance:Misc:001020304012XbarChartby人SampleMeanMean=18.35UCL=20.86LCL=15.8400123456712RChartby人SampleRangeR=2.45UCL=6.307LCL=012345678910010203040C4人人*C4InteractionAverage1212010203040人By人12345678910010203040C4ByC4%Contribution%StudyVarGageR&RRepeatReprodPart-to-Part050100ComponentsofVariationPercentGageR&R(ANOVA)for数据StdDevStudyVar%StudyVarSource(SD)(5.15*SD)(%SV)TotalGageR&R1.66098.553714.51Repeatability1.52757.866813.34Reproducibility0.65223.35865.70人0.00000.00000.00人*C40.65223.35865.70Part-To-Part11.327958.338698.94TotalVariation11.449058.9624100.00NumberofDistinctCategories=10AttributeAgreementAnalysisforA1,A2,B1,B2,C1,C2WithinAppraisersAssessmentAgreementAppraiser#Inspected#MatchedPercent95%CI11010100.00(74.11,100.00)21010100.00(74.11,100.00)31010100.00(74.11,100.00)#Matched:Appraiseragreeswithhim/herselfacrosstrials.Fleiss'KappaStatisticsAppraiserResponseKappaSEKappaZP(vs0)1010.3162283.162280.0008110.3162283.162280.00082010.3162283.162280.0008110.3162283.162280.00083010.3162283.162280.0008110.3162283.162280.0008BetweenAppraisersAssessmentAgreement#Inspected#MatchedPercent95%CI1010100.00(74.11,100.00)#Matched:Allappraisers'assessmentsagreewitheachother.Fleiss'KappaStatisticsResponseKappaSEKappaZP(vs0)010.081649712.24740.0000110.081649712.24740.0000AppraiserPercent32111010090807095.0%CIPercentDateofstudy:Reportedby:Nameofproduct:Misc:AssessmentAgreementWithinAppraisersWithinAppraisers各个检验员的重复性百分比超过