theyieldofGrindBeadproducts-GB(六西格码项目

ContinuousImprovementIncreasetheyieldofGrindBeadproducts-GBLairdTechnologiesSixSigmaGBProjectDefinePhaseContinuousImprovement2ProjectSummaryProjectTitleIncreasetheyieldofGrindBeadproducts-GBProjectScopeGrindBeadGreenBelt******DeploymentChampion******ProcessOwner******FinanceRepresentative******Mentor******ContinuousImprovement3ProjectTeamMembersTeamMembers&DepartmentsLeader:******------ProcessEngineerMember:******------ProcessEngineer******------ProductionSupervisor******------ProductionSupervisor******------ProductionSupervisor******------QASupervisor…ContinuousImprovement4ProblemStatementProblemStatement•TheyieldofGrindBeadproductsis77.53%fromJan-2010toMay-2010,whichimpactedFGTSseriouslyProjectObjective•Increasetheyield:From77.53%to90%bytheendofSep.2010•BusinessBenefits•ProjectedAnnualSavingsof$30K•MeetCustomerDeliveryContinuousImprovement5ProjectBackgroundComment:GrindBeadYieldismorelowerthantheotherproducts.GrindBeadYieldreport60%65%70%75%80%85%90%95%100%JanFebMarAprMayJunJulAugSepOctNovDecTargetActualContinuousImprovement6ProjectBackgroundComment:1.GrindBeadbelongtoS100products.2.ThetotalyieldofS100iscloseto90%.S100TotalYield60.0%65.0%70.0%75.0%80.0%85.0%90.0%95.0%100.0%JanFebMarAprMayJunJulAugSepOctNovDecContinuousImprovement7ProjectMetricsGrindBeadYieldreport60%65%70%75%80%85%90%95%100%JanFebMarAprMayJunJulAugSepOctNovDecTargetActual•12.5%roomofimprovementBaseline=77.5%Target=90%ContinuousImprovement8ProjectTimeFrame(Milestone)Define2010.06.01Measure2010.07.01Analyze2010.07.30Improve2010.08.20Control2010.09.01ContinuousImprovement9FinancialImpact&SavingAssessedsaving=StandardCost*Forecast*(BaselineScraprate-TargetScrapRate)=USD30KActualSavingFromOctToDec:ActualSaving=USD59.4KContinuousImprovement10Summary–Deliverables&Conclusion•GrindBeadYieldwas77.5%fromJantoMay-2010,thereisabout12.5%potentialdefectratioreductiontoachievetarget90%bytheendof2010.•ProjectedAnnualSavingsof$30KMeetCustomerDeliveryContinuousImprovement11IncreasetheyieldofGrindBeadproducts-GBLairdTechnologiesSixSigmaGBProjectMeasurePhaseContinuousImprovement12ParetoChartComment:1.ScrapdataisfromproductdailyreportinMay-20102.IntheParetoChartofDefectItem,Loss,chipandsamllIDoccupy99.0%oftotalscrapqty.Sotheyshouldbemainimproved.MainimprovedefectsContinuousImprovement13ParetoChartanalysisComment:Losscomefromthemanagement,Itmeanstheproductsdropawayduringthetransferring.Wehadarrangedameetingwithproduction.Pleaseseethebelowmeetingsummary.Afterproductionimproved,theParetoChartshowthemaindefectsareSmallIDandChips.关于少数的a.成型称对批量数量叶华飞韩应明(负责培训)2010-8-25b.各工序培训员工注意搬运手势避免掉落损坏产品S100所有班组长(负责培训)2010-8-25ContinuousImprovement14ParetoChart-Sep.2010Comment:1.ScrapdataisfromproductdailyreportinMay-20102.IntheParetoChartofDefectItem,chip,samllIDandLossoccupy99.0%oftotalscrapqty.Sotheyshouldbemainimproved.MainimprovedefectsSmallIDChipLossContinuousImprovement15ProcessMapContinuousImprovement16IdentifyKPIVsManmaterialMethodEnvironmentLustrationDryness5SCostumeTechnicianskillGaugeInspectioncriteriaInspectionmethodWI(x)Operatorsskill(x)MachineMeasureKilnGrindingmachinePressingmachineSpeedDiamondwheel(x)CleaningStainlesstrayPressmachineLCRmeterProfileprojectorSamplesPO2PackageBoxesSelfcontrolConsciousnessSmallIDWItraining(x)SpeedPlasticbagsWorkstandardCleaningroomAirconditionPowderLotnoPowdersizeAdaptthemachinePressconditionFiringprofilePowderpropertiesWashingprocedureContinuousImprovement17IdentifyKPIVsManmaterialMethodEnvironmentLustrationDryness5SCostumeTechnicianskillGaugeInspectioncriteriaInspectionmethodWI(x)Operatorsskill(x)MachineMeasureKilnGrindingmachinePressingmachineSpeedDiamondwheel(x)CleaningStainlesstrayPressmachineLCRmeterProfileprojectorSamplesPO2PackageBoxesSelfcontrolConsciousnessChipWItraining(x)SpeedPlasticbagsWashingprocedureWorkstandardCleaningroomAirconditionPowderLotnoPowdersizeAdaptthemachinePressconditionFiringprofilePowderpropertiesContinuousImprovement18FMEAContinuousImprovement19FMEAContinuousImprovement20GageR&RSmallIDContinuousImprovement21ControlChartControlChartIDdimensionComments:InAugof2010,SmallIDactualscraprateis17.01%；Sigmalevel(ZValue)is0.013SampleSampleMean109876543211.801.791.781.771.76__X=1.78UCL=1.79744LCL=1.76256SampleSampleRange109876543210.080.060.040.020.00_R=0.03024UCL=0.06394LCL=011Xbar-RChartofS10T050917ContinuousImprovement22PotentialKPIVsList•AccordingtoanalysiswefoundfourpotentialKPIVs:1.Pressingprocess—Pressingcondition(SPI)2.Firingprocess—Temperaturesettings3.Grindingprocess—Washingprocedure4.Managementprocess—SourcingchainContinuousImprovement23•MeasurePhaseDeliverables•DevelopedtheParetoCharts•Developedprocessmapping•DevelopedFishboneDiagramandFMEA•IdentifiedpotentialKPIVsDeliverables&Conclusion•ConclusionFromMeasurePhase•WehadconfirmedtheMeasuresystemGageR&RisOK.•ThroughProcessmap,FishboneDiagram,C&EMatrix,FMEAanalysis,wefound4KPIVs.•WehadmadetheActionPlanfor4KPIVs.ContinuousImprovement24IncreasetheyieldofGrindBeadproducts-GBLairdTechnologiesSixSigmaGBProjectAnalysisPhaseContinuousImprovement25PotentialK