IQA_Project

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Project Title

CLI-IQA Cycle Time Reduction and Inspector Productivity Improvement

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Project: Improvement of CLI –IQA Inspection

Turn around Time and Productivity

Project Start: January 2, 2007

Project End: July 31, 2007

Location: Laguna, Philippines

Champion: Lito FLores

Process Owner: Ferdinand Cruz

Green Belt: Ferdinand Cruz / Jonash Rocamora

Team Members: Joszal Anchoriz, Alvin Ibanez, Tina

Mendoza, Sunny Caparas

Problem Statement:

After the acquisition of Powerwave Philippines by Celestica (Mar 2006), now known as Celestica Laguna Inc. Different commodity network Teams (e.g. IC, Logic, Metals, PWB, Discrete, Passive, Power Supply, Optics and Plastics ) and metrics ( e.g. Turn Around Time, SPM, SCAR etc.) were introduced. The separation/resignation of two IQA inspectors (Reinor and Myla) and the addition of new products such as Halfdome (April 2006) and Royale (July 2006) resulted to massive parts queue for inspection at IQA. Previous Inspection turn Around Time (cycle time) from an average of 72 hours to 20 hours Celestica corporate/regional requirement should be met. Regular submission of reports such SQE Global reports, Supplier Performance Measurements (SPM), Supplier scorecards should also be accomplished and submitted.

Objective Statement:

• Improve inspection cycle time from previous average target of 72 hours to average of 20 hours.

• Maximize IQA space to accommodate more parts queue for inspection.

• Increase inspectors productivity by 20% from average of 17 line items inspected to 20 line items (without NCMR) for 10 hr/shift work schedule and 7 to 12 line items with some NCMR.

• Fast and accurate data retrieval from manual paper trail to computerized data miner

Current Project Savings: To be computed/ To be determined

Project Phase:

Accomplishments: Team formation/ Organization, DONE ww01 2007 Macro Mapping of Process , DONE ww01 2007 Data Gathering , DONE ww02 2007 Data Analysis, DONE ww03 2007 Program logic / flow discussion with IT, DONE ww04 Programming of sub-modules and major modules including screenshots, Started ww05 2007 Review/test completed sub modules and major modules, ww06 2007 Program debugging ( as needed) Part number set-up and inspection requirement set-up, Started ww07 2007 as needed. Set-up hardware requirements and PR additional requirement to support full

implementation. DONE ww07, 2007 Review IQA layout and material flow. DONE ww07 2007 Re-layout IQA according to plan. DONE ww7 2007 Train IQA inspector on how to use the program ww08 2007 Start parallel paper trail method and automated QA records, DONE ww08 2007 (All Inspectors) Roll-out automated QA records without paper QA records with two inspectors. Linked QA records to MID system eliminating redundant encoding of parts traceability, 4/15/07 Full implementation of Automated QA records to all IQA inspectors, May15, 2007 Auto report (SQRR) module, May 15, 2007

To Do’s: Pilot run Auto report (SQRR) on ww21 report Enhance Auto reports program (SQRR) Target Date June to July 2007 Revise IQA procedure to document the system change , Target Date June 2007

Project Summary:

Completed QA records minor and major modules programming. Started using the QA records parallel with the manual paper trail method for comparison and buy-off purposes. Pilot run of the QA records were successful . Two inspector were tasked to use the QA records without the paper trail (inspection records). Daily review of the QA records shows that the two inspectors were able to utilize the system properly. Full benefits of the system will be realized after completion of the auto reports generation and auto IDR/IR generation in case of failed inspection result.

Opportunities:

(Consider the next utilizations of achieved results)

Six Sigma Project Summary

D M A I C

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Project: Improvement of CLI –IQA Inspection

Turn around Time and Productivity

Project Start: January 2, 2007

Project End: July 31, 2007

Location: Laguna, Philippines

Champion: Lito FLores

Process Owner: Ferdinand Cruz

Green Belt: Ferdinand Cruz and Jonash Rocamora

Team Members: Joszal Anchoriz, Alvin Ibanez, Tina Mendoza, Sunny Caparas

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Problem Statement:

After the acquisition of Powerwave Philippines by Celestica (Mar 2006), now known as Celestica Laguna Inc. Different commodity network Teams (e.g. IC, Logic, Metals, PWB, Discrete, Passive, Power Supply, Optics and Plastics ) and metrics ( e.g. Turn Around Time, SPM, SCAR etc.) were introduced. The resignation of two IQA inspectors and the addition of new products such as Halfdome (April 2006) and Royale (July 2006) resulted to massive parts queue for inspection at IQA. Previous Inspection turn Around Time (cycle time) target of 72 hours from the time parts received at IQA until parts approval were not measured effectively since the current ERP (Baan) system measures the cycle time from Receiving time up to part approval. Currently 20 hours T.A.T. Celestica corporate/regional requirement should be met. Regular submission of reports such SQE Global reports, Supplier Performance Measurements (SPM), Supplier scorecards should also be accomplished and submitted on time.

Objective Statement:

• Effectively measure IQA inspection cycle time and meet 20 hours target.

• Maximize IQA space to accommodate more parts queue for inspection.

• Increase inspectors productivity by 20% from average of 17 line items inspected to 20 line items (without NCMR) for 10 hr/shift work schedule and 7 to 12 line items with some NCMR.

• Fast and accurate data retrieval from manual paper trail to computerized data miner

Current Project Savings: To be computed/ To be determined


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Project Phase:

Accomplishments: Team formation/ Organization, DONE ww01 2007 Macro Mapping of Process , DONE ww01 2007 Data Gathering , DONE ww02 2007 Data Analysis, DONE ww03 2007 Program logic / flow discussion with IT, DONE ww04 Programming of sub-modules and major modules including screenshots,

Started ww05 2007 Review/test completed sub modules and major modules, ww06 2007 Program debugging ( as needed) Part number set-up and inspection requirement set-up, Started ww07 2007 as needed. Set-up hardware requirements and PR additional requirement to support full

implementation. DONE ww07, 2007 Review IQA layout and material flow. DONE ww07 2007 Re-layout IQA according to plan. DONE ww7 2007 Train IQA inspector on how to use the program ww08 2007 Start parallel paper trail method and automated QA records, DONE ww08 2007 (All Inspectors) Roll-out automated QA records without paper QA records with two inspectors. Linked QA records to MID system eliminating redundant encoding of parts traceability, 4/15/07 Full implementation of Automated QA records to all IQA inspectors ,DONE May 15, 2007 Auto report (SQRR) module, May 15, 2007

To Do’s:

Pilot run Auto report (SQRR) on ww21 report Enhance Auto reports program (SQRR) Target Date June to July 2007 Revise IQA procedure to document the system change , Target Date June 2007


D M A I C

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Project Summary:

Completed QA records minor and major modules programming. Started using the QA records parallel with the manual paper trail method for comparison and buy-off purposes. Pilot run of the QA records were successful . Two inspector were tasked to use the QA records without the paper trail (inspection records). Daily review of the QA records shows that the two inspectors were able to utilize the system properly. Full benefits of the system will be realized after completion of the auto reports generation and auto IDR/IR generation in case of failed inspection result.

Opportunities:

(Consider the next utilizations of achieved results)


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Team Organization

Lito Flores(Champion)

Ferdie CruzJonash Rocamora

(Green Belt)

Team MembersJoszal AnchorizSunny Caparas

Alvin IbanezTina Mendoza

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Macro Map

Parts received from supplier at Receiving

QTY Audit verification

Baan/System Encoding

Endorse item to IQA

Record to logbook

Refer to priority list

from Planning

Perform Inspection

Prepare Quality

Records

Baan Transaction

MID Generation

Prepare NCMR

Receiving

Process Non-Value Add

Non-Value add but essential

Record to logbook X

Refer to priority list from planning X

Perform inspection X

Baan Transaction X

MID generation X

Prepare Quality records X

NCMR Preparation X

Endorse parts to warehouse & log X

Note:

Process inside dotted lines are activities outside IQA

Endorse parts to Warehouse

and log to logbook

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Data Gathering

Productivity Monitoring (1 month Data)

•Highlighted in yellow are not full time inspectors•Highlighted in gray are new inspectors•Encircled are the max line items inspected by full time inspectors•Maximum Line items that can be inspected in a 10 hr shift schedule = (14+19+19) / 3 = 17 line items (without Failure/NCMR) using old inspectors as base line.

•Average Line items that can be inspected in a 10 hr shift schedule with some NCMR preparation = (6+6+9) / 3 = 7 line items

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Analyze

Inspection Turn Around Time

People Materials Work Methods

Environment Equipment

Skills

Education

Work Attitude

Not Motivated

Low Salary

High Volume

Large geometry and parameters to inspect Manual paper Trail

method

Inspection, endorsement,

approval, docs done by one inspector

Insufficient manpower

Not comfortable

Warm / cold

Crowded work space

Sharing of test equipment

Proximity to inspection area (CMM, ht gages

etc.)

Old equipment

`Uses Baan

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Analyze

Received parts from Receiving

Allocate parts to

inspectors

Perform Inspection

Baan Transaction

MID Generation

Quality Records

NCMR/ IDR

Endorse Parts

Record parts details on log sheet

PO#/ /Receipt #

Quantity

Record endorsement

details on log sheet

Endorse by

Received by

Inspect according Refers to

priority list

Inspect according to

age

Waiting for priority list

from planning

Waiting for part

age status

from IT

AML Check

Refer to Baan for

AML Check

Visual inspection

Dimensional Inspection

Electrical test

Create NCMR manually

System rejection

Refers to quality

record and master list

Manually Record parts

traceability details

Auto generate MID

number

Part No

Lot code/date code

Manually Record parts

traceability details

inspector

IR No./ Part Number

Redundant / repeated

Take picture

Manually Draft the

report with parts details

Create IDR manually for

MRB purposes

Manually write parts

rejection details and inspection

details

Manually pull-out quality

records folder

Endorse parts to ware

house

Record endorsement

details on log sheet

System Approval

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AnalyzeCurrent VSM Considering no failure

Note: Highlighted in yellow are process that can be improved

IQA VSM Before

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Improvement

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Analyze

Activity Off the shelf Item (e.g. Component)

Approval 0.717

Inspection 8.317

Manual/Paper Method 10.000

Staging and Endorsement 2.850

Traceability 10.517

Total 32.400

Off the shelf Item (e.g. Component) Inspection Elements

2%

26%

31%

9%

32%

Approval

Inspection

Manual/PaperMethod

Staging andEndorsement

Traceability

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Analyze

Custommized Items (e.g. Mech'l, PCB, Cable) Inspection Elements1%

75%

11%

2%

11%

Approval

Inspection

Manual/PaperMethod


Traceability

Activity Custommized Items (e.g. Mech'l, PCB, Cable)

Approval 0.717

Inspection 106



Traceability 15.75

Total 140.137

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Analyze

Consumables Inspection Elements3%

27%

35%

9%

26%

Approval

Inspection

Manual/PaperMethod


Traceability

Activity Consumables

Approval 0.75

Inspection 8.1



Traceability 7.713

Total 29.995

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Main Program GUI’s

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MAJOR MODULES

ITEM MODULE DESCRIPTION USER SCREEN SHOT REMARKS

1 IR FormInspectionReportFrom

Generates an excel file with an automated serial IR number, a form used by IQA to record the quality inspection of the item. (For hard copy purposes)

ALL IQA

Status Completed: This tool create inspection report form with smart serial numbers. This also eliminates the purchase of carbonized IDR forms used during MRB and parts disposition at IQAAverage IDR Form consumption Is about 4 rims per month.

To be used for failed Status only

2 ITEM STATUS

A module that is designed to monitor the flow of material and its status at IQA. It alerts all concern engineer, planners, managers, finance personnel regarding the item on hold/pending at IQA.

ALL Status Completed: This session allows SQE and IQA staff to work continuously without interruption from different person making follow-ups and asking for parts status. Previously tracking of parts status were done manually and usually summary status were released the following day. With the use of this tool everything is just a click away.

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MAJOR MODULES


3 CYCLE TIME

Tracks the actual time and date received of the items endorsed by receiving personnel.

ALL IQA

Status completed . This modules eliminates manual tracking of date and time the parts were received, this is essential for the computation of actual inspection turn around time. The inspector would just have to key-in the receipt number and all items contained on that receipt will automatically tagged with the actual date and time it was received by IQA. Target inspection completion date is also computed automatically. This replaces manual recording and log books.

4 QA RECORDS

Maintains details and status of incoming inspection per part number (visual inspection, dimensional, electrical and document requirement)

ALL IQA

Status: In Progress, ongoing elimination of program glitch. This module will replace the Quality Records folder that are used to record and trace parts history . In return purchase of quality records folder is also eliminated.

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MAJOR MODULE


5 MID A system that generate and print a unique serial number used to identify the material after inspection. (pass tracking of material used)

ALL IQA

Status: Existing system during REMEC times. This system was modified to fit the current need of Celestica Laguna operations. Inspector can now assign MID number in online or offline mode. Previously when the Baan system is down, parts approval and MID generation is not possible. With the introduction of manual MID session MID assignment is now possible without any compromise because the online and offline database are the same eliminating double MID number.

6 DATA MINER

The program is design to gather information and data collection and can extract information in excel format. The system support the following modules: MID, For Approval, & Inspection Record.

ALL IQA

Status: Completed. This tool replaces the tedious method of retrieving parts history/traceability.Previously, when parts info such as lot code or date code is required hard copies of quality records are retrieved from archive, but with this new tool everything is available in just a click of a finger tips.

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OTHER MAINTENANCE SUB-MODULE


1 CYCLE TIME CALENDAR

Maintains inspection working days for cycle time reference.

SYSTEM

ADMIN /CLERK/

SQE

Status: Completed. This sub-module supports the Cycle Time Module. The System Admin/Clerk/SQE manage the session by identifying the dates without work schedule such as weekends and holidays which should not be included in the cycle time computation.

2 AQL SETUP Maintains the Accept Quantity Lot (AQL) table as being referenced in the QA Records module.

SYSTEM

ADMIN /CLERK/

SQE

Status: Completed. The System Admin/Clerk/SQE manage this session by defining the AQL percentage and level according to define lot size ranges.

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3 COMMODITY TYPE

Maintains the list of all commodity type

SYSTEM

ADMIN /CLERK/

SQE

Status: Completed, This session is manage by the System Admin/Clerk/SQE in reference with the commodity grouping provided by corporate/regional SQE. This supports the QA records module and the part number set-up sub-module. This identifies the commodity type a part number belongs.

4 COMMODITYCODE

Maintains the list of all parent commodity codes in a commodity group

SYSTEM

ADMIN /CLERK/

SQE

Status: Completed, This session is manage by the System Admin/clerk/SQE in reference with the commodity grouping provided by corporate/regional SQE. This supports the QA records module and the part number set-up sub-module. This identifies the commodity group where the part number belongs.

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5 COMMODITY GROUP

Maintains the list of all commodity sub-group codes being mapped in component part numbers.

SYSTEM

ADMIN /CLERK/

SQE

Status: Completed, This session is manage by the System Admin/clerk/SQE in reference with the commodity grouping provided by corporate/regional SQE. This supports the QA records module and the part number set-up sub-module. This identifies the commodity group.

6 DEFECT SETUP

Maintains the list of all defects by commodity encountered at incoming inspection.

SYSTEM

ADMIN /CLERK/

SQE

Status: Completed, This modules allows the System Admin/Clerk/SQE to identify all possible defects per commodity. This support the QA records inspection details.

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7 ITEM STATUS (For Approvals) REMARKS SETUP

Contains the list of status of item in for Item Status module.

SYSTEM ADMIN /CLERK/S

QE

Status: Completed, In this session the System Admin/Clerk/SQE define remarks category e.g. MRB, Non COC etc.

8 LOCATION SETUP

Contains the list of all location of defect encountered at incoming inspection.

SYSTEM ADMIN /CLERK/S

QE

Status: Completed. In this session the System Admin/Clerk/SQE define all possible location of defects e.g. top, side, etc.

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9 PACK SETUP

Contains the list of all type of material packaging.

SYSTEM

ADMIN /CLERK/

SQE

Status: Completed. In this session the System Admin/Clerk/SQE define all possible packaging available. This support the QA records module

10 PART NUMBER SETUP

A module which specifies the details of the item particularly the commodity group, type, and its application.

SYSTEM

ADMIN /CLERK/

SQE

Status: Completed, This session supports the QA records modules. The SQE/System Admin/Clerk define parts New commodity, commodity group and commodity type details.

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11 UNIT OF MEASURE

Contains the list of all unit of measurement for media use at incoming inspection.

SYSTEM

ADMIN /CLERK/

SQE

Status: Completed. This is the session where the unit of measurement is define by the System Admin/Clerk/SQE e.g. cm, inches, mm, microns etc.This supports the QA records inspection details.

12 AML Retriever

This module allows the user to check the existing AML without using the Baan

ALL Status: Completed

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13 COC Up loader

Uploads the COC softcopy into the IQA database

ALL Status: CompletedAllows the IQA to upload soft copy of COC into the system, making future retrieval faster and eliminate possible loss of documents. It also lessen the paper for retention that requires space and other resources.

14 Media Used Maintains the list of all measuring equipment used

SYSTEM

ADMIN /CLERK/

SQE

Status: Completed, This modules allows the System Admin/Clerk/SQE to identify all possible MTE and inspection media used during inspection. This support the QA records inspection details.

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Tangible Benefits

Factors Before EXPECTED

Recoverability of data

Retrievable in couple of hours or even longer depending on the extent or details needed.

With the use of data miner module of the data base, data retrieval is possible in minute or less

Resources Required papers, forms, cabinet and large storage space to house document for temporary repository and archiving.

Minimal resources needed, eliminated other forms being used and the need for additional cabinets and space for repository and archiving.

Accessibility/availability

Used to take couple of hours to identify status of all raw materials at IQA location, every line item has to checked manually from time to time versus the list provided by IT clerk. Information was disseminated to concerned person thru phone call and e-mails.

Made readily accessible in real time. Engineers, Buyers, Planner, Finance Personnel and Managers can now view the actual parts status queue at IQA whether it is For Inspection, HOLD, for MRB disposition, for RTV, etc.

Record Security Paper records can be misplace, lost or damage over time Incoming quality material record (soft copy) is secured and regularly back-up in the network and remote location

Cycle TimeMeasurement

Cycle time measurement is computed using a separate excel file because the cycle time measured by Baan is from the time of parts received up to parts approval in the system. This includes the MRB time, hold time, receiving time. Etc.

With the use of cycle time module, cycle time can be measured automatically from the actual time of endorsement of parts to IQA up to complete inspection. Manual logging on logbook and encoding on excel file was eliminated.

Savings Need to allocate CAPEX for the purchase of locally available software.

Realized approximately $2800 of savings as the database was developed in house

Connectivity Uses paper trail method, connectivity to ODC is not possible. Current ODC capability is from SMT to Box build.

Linkable to ODC making traceability from IQA inspection to Box built possible.

Productivitymonitoring

Monitors manually, checking done at the end of the shift or every start of the shift.

Can determine productivity of each inspector quickly through the data miner module.

Data Accuracy Summary of failure were collected and summarized manually Summary are populated automatically with the use of data miner.

Headcount Requires replacement for the two resigned employee Man-hour requirement were covered by the productivity improvement. Therefore replacement is not needed

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Intangible benefits

•Demonstrated CAN DO ATTITUDE, the team created a new tool even with limited resources available. The limited working schedule and skills set has never been an issue to the team to complete the project. The team patiently worked together and reached their goal.

•TEAM WORK was exemplified by the team members. The member of the group are from different departments with different tasks, but were able to work as one to reach a common objective of making IQA operation easy. The teams synergy produced an effect greater than the sum of their individual capabilities.

•The team’s morale was uplifted. The development of the project provided them confidence and a sense of accomplishment. They feel proud of what they have done

Date post:	20-Jan-2017
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IQA_Project

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