Page i. PROJECT BACKGROUND : POM (Power) is one of the segments from Infineon Malacca which producing various types of Semiconductor Automotive applications products. M2 Dpak production line in Power segment is one of the high demand production lines producing approximately 23 mio pieces per week. Trim & Form (TNF) process is one of the key processes in Backend semiconductor to singulate the leadframe into unit form. Warriors is a Self-Managing Teams (SMTs) from Trim & Form which consists of 8 members that formed by 4 technicians and 4 operators from production shop floor. Self-Managing Teams (SMTs) in the production lines is developed to ensure that Key Performance Indicator like Quality, Cost, Delivery, Morale and Safety are met as per company target. Small Group Activities (SGA), comprising from 3 groups of SMT are taking the challenge to run the project. As known, yield is one of the leading KPI metric in order to measure product’s quality. The team realized that Trim & Form yield is not able to achieve company target of 99.8% with total of 0.63% losses which mainly contributed by 0.59% of Body to Ground (BTG) defect. With this, the team decided to take up the challenge to improve Trim and Form yield by reducing Body to Ground (BTG) rejects from 0.59% to 0.16% (July to December FY 14/15). ii. MOST POSSIBLE CAUSE(s) : According to the Pareto breakdown, 0.59% of Body to Ground reject is causing by five hypotheses inclusive of the failure from machine Rocker Arm, Forming Punch, Forming Spring, Forming Pusher and Waste Lead Stuck in the TNF process. Further data analysis shown that highest reject is due to Rocker arm failure with the highest count of 28 times Per Quarter. Worn-out roller bush and push pin are found while doing analysis study. iii. PROPOSED INNOVATION & CREATIVE SOLUTION (s) : The team decided to change the Copper Bush on Rocker Arm to Single Piece Solid design (Steel / K110). Implementation of this solution has resulted in reducing of Body to Ground reject, however it is only achieved 0.18% improvement which still fa r away from initial target. After further brainstorming and inspiring by the seesaw concept, the team found out that rocker arm base dimension is definitely playing an important role to make lead forming. With this new design of rocker arm base dimension changed, BTG reject has reduced by 0.43%. iv. BENCHMARK : Yield target to be improve from 99.37% to 99.8%
Transcript
Page
i. PROJECT BACKGROUND :
POM (Power) is one of the segments from Infineon Malacca which producing various types of Semiconductor Automotiveapplications products. M2 Dpak production line in Power segment is one of the high demand production lines producingapproximately 23 mio pieces per week. Trim & Form (TNF) process is one of the key processes in Backend semiconductor tosingulate the leadframe into unit form. Warriors is a Self-Managing Teams (SMTs) from Trim & Form which consists of 8 membersthat formed by 4 technicians and 4 operators from production shop floor. Self-Managing Teams (SMTs) in the production lines isdeveloped to ensure that Key Performance Indicator like Quality, Cost, Delivery, Morale and Safety are met as per company target.Small Group Activities (SGA), comprising from 3 groups of SMT are taking the challenge to run the project.
As known, yield is one of the leading KPI metric in order to measure product’s quality. The team realized that Trim & Formyield is not able to achieve company target of 99.8% with total of 0.63% losses which mainly contributed by 0.59% of Body toGround (BTG) defect. With this, the team decided to take up the challenge to improve Trim and Form yield by reducing Body toGround (BTG) rejects from 0.59% to 0.16% (July to December FY 14/15).
ii. MOST POSSIBLE CAUSE(s) :
According to the Pareto breakdown, 0.59% of Body to Ground reject is causing by five hypotheses inclusive of the failure from machine Rocker Arm, Forming Punch, Forming Spring, Forming Pusher and Waste Lead Stuck in the TNF process. Further data analysis shown that highest reject is due to Rocker arm failure with the highest count of 28 times Per Quarter. Worn-out roller bush and push pin are found while doing analysis study.
iii. PROPOSED INNOVATION & CREATIVE SOLUTION (s) :
The team decided to change the Copper Bush on Rocker Arm to Single Piece Solid design (Steel / K110). Implementation of this solution has resulted in reducing of Body to Ground reject, however it is only achieved 0.18% improvement which still far away from initial target. After further brainstorming and inspiring by the seesaw concept, the team found out that rocker arm basedimension is definitely playing an important role to make lead forming. With this new design of rocker arm base dimension changed, BTG reject has reduced by 0.43%.
iv. BENCHMARK :
Yield target to be improve from 99.37% to 99.8%
Page
vi. AWARD, REWARD & RECOGNITION :
Champion of Infineon Malacca internal SGA competitionGOLD Award for Northern Region ICC Team Excellent 2016
vi. PROJECT PIC TURE(s) :
v. PROJECT ACHIEVEMENT & VALUE CREATION :
1) Successfully reduced BTG rejection from 0.59% to 0.16%.2) Overall TNF yield losses reduced from 0.63% to 0.45%
Page
CW - Calendar Week
QCDMS - Quality, Cost, Delivery, Morale & Safety
ESH - Environment, Safety & Health
FAR - Failure Analysis Report
PC - Process Control
BTG - Body To Ground
JHAM - Jishu Hozen Autonomous Maintenance
PM - Preventive Maintenance
STS - Strip To Strip
RTR - Reel To Reel
CPP - Cost Per Piece
BY - Business Year
OEE - Overall Equipment Effectiveness
SMT - Self Managing Team
DDM - Deviation & Decision Management
MAL - Melaka
SPC - Statistical Process Control
GCM - Global Change Management
YIP - Your Idea Pays
SOP - Standard Operation Procedure
OJTI - On Job Training Instruction
TWI - Training Within Industry
KPI - Key Performance Indicator
ABBREVIATION
Page 4
Page 5
Page
Our Team Members Profile
INTRODUCTION
6
Education level : SPM to DiplomaAverage Years of Service : 6 Years
Mohd Khair – C shift• Line Technician• 5 years service • 1st project
Mohd Khair – C shift• Line Technician• 5 years service • 1st project
Mohd Khair – C shift• Line Technician• 5 years service • 1st project
Mohd Khair – C shift• Line Technician• 5 years service • 1st project
Saiful Nizam - C shift• Production Technician• 3 years service • 1st project
Sheikh Yusri - C Shift• Operator• 4years service • 1st project
Nur Shatila - A Shift• Operator• 3 years service • 1st project
Nurathirah - A Shift• Operator• 3 years service• 1st project
Azrul Hisham– OH• Maintenance•13 years service • 2nd project
New members
62.5%
Experienced members
37.5%
Members are selected
from various
shift and
Designation
Phillips– B shift• Shift Maintenance• 14 years service • 2nd project
M. Rahimy– A shift• Line Technician• 6 years service • 2nd project
Qurratu Aini - C Shift• Operator• 3 years service • 1st project
CoordinatorRosli Ismail
FacilitatorMr. Tan Say Kee
PagePage 7
Page
Evidence of Involvement~ Matrix Diagram ~
CRITERIA 1.1: INTRODUCTION OF PROBLEM
8
ACTIVITIESTOOLS/TECHNIQUESUSED
INTRODUCTION
PROJECT
SELECTION & DEFINITION
IMPROVEMENTOPPORTUNITIES ANALYSIS
CREATIVE & INNOVATIVESOLUTIONS / IMPLEMENTATION
MONITORING & STANDARDISATION
ACHIEVEMENT &VALUE CREATION
PRESENTATION
InvolvementCoordinator
Flow Chart, Check sheet,
PDCA, Gantt Chart, Radar Chart, Bar Graph
PDCA, Gantt Chart, Bar chart, Matrix
Diagram, Data, DDM Trend, Pareto Diagram
5W & 2H, 5W 1H, Brainstorming, Fish Bone
diagram, Tree Diagram, Why-Why Analysis
Check sheet, 5W & 1H, Brainstorming, 4R,
Why-Why Analysis
Bar Graph, SPC, TWI, Check sheet
Bar Graph, Check sheet
Presentation Skill, Training Technique,
Coaching Skill
Buddy System :Experienced members will guide
and train new members
100% Team
Involvement
By Using
Buddy System
Page
Evidence of Involvement~ Planning Our Activities using Gantt Chart ~
CRITERIA 1.1: INTRODUCTION OF PROBLEM
9PLAN
C
D
P
A
Page
Team Applied QC Tools to Monitor Project~ Progress using PDCA Approach ~
CRITERIA 1.1: INTRODUCTION OF PROBLEM
10
PDCA
C
H
E
C
K
A C T I O N
D O
• Problem identification - Analyze and identifiedproblem - Set project focus and objectives
• Screening problem
• Containment action• Suggestion on various alternative
solution
• Analyze the result of
trial run - Further Verification
• Implement Best Solution/trial-run
• Implement project - Compare
result target - Monitoring
Activities
1)Collect data :
- Knowledge Management
- Primary & Secondary
data (historical data)
- Internet surfing
- Process Engineer
2) Compile data
3) Identified problem
4) Brainstorming
Activities
1) OJTI - TWI
2) Implement new design
of rocker arm to all FICO
Machine
3) Best practice sharing
Activities
1) Monitoring results on
pilot implementation
2) See-saw concept
Pareto Chart
Bar Graph
Check Sheet
Bar Graph
Gantt Chart
Pareto Chart
Tree
Diagram
Why Why
Analysis
5W 1H
Cause &
Effect
Diagram
Check Sheet
Bar Graph
Check Sheet Bar Graph
Check Sheet
P
L
A
N
Activities
1) Implement the plan
2) Begin analysis of
the data
Page
How Project was Selected~ Key Performance Indicator at Trim & Form ~
CRITERIA 1.1: INTRODUCTION OF PROBLEM
11
Quality No of FAR casesTarget :0 caseTo date : 0 case
0.0
1.0
2.0
3.0
15 16 17 18 19 20 21 22 23 24 25 26
CW
Cu
sto
me
r C
om
pla
in
Morale AttendanceTarget : 95%To date : 98.5%
70.0
80.0
90.0
100.0
15 16 17 18 19 20 21 22 23 24 25 26
CW
Att
en
da
nc
e
(%)
DEPARTMENTAL
TOP 5 TARGET 2015
BELOW TARGET
PLAN
TARGET
STRETCHED TARGET Delivery Output Trim & Form
processTarget : 22M / weekTo date : 22.5M / Week
0.0
1000.0
2000.0
3000.0
15 16 17 18 19 20 21 22 23 24 25 26
CW
Att
en
da
nc
e
(%)
Accident severity rate under ESH departmentTarget : 0 caseTo date : 0 case
Safety
0.0
2.0
4.0
6.0
8.0
10.0
15 16 17 18 19 20 21 22 23 24 25 26
CW
Ac
cid
en
t
YieldTarget : 99.8%To date : 99.37%
Cost
97
97.5
98
98.5
99
99.5
100
15 16 17 18 19 20 21 22 23 24 25 26
CW
YIE
LD
(%
)
YieldTarget : 99.8%To date : 99.37%
Cost
97
97.5
98
98.5
99
99.5
100
15 16 17 18 19 20 21 22 23 24 25 26
CW
YIE
LD
(%
)
Page
How Project was Selected~ Yield at Trim & Form Issues ~
CRITERIA 1.1: INTRODUCTION OF PROBLEM
12
Page
Why Project was Selected~ Evaluate and Analysis ~
CRITERIA 1.1: INTRODUCTION OF PROBLEM
13
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
15 16 17 18 19 20 21 22 23 24 25 26 27
Chip Casing Lead Sweap Scratches Burr at LeadBurr at Heatsink Body to Ground Target
0.16%
CW
To
tal R
eje
ct
Historical Data of Overall YIELD Losses at TRIM & FORM Process
Data obtained from Process Engineer (Winnie Goh)
Verified data by Maintenance /Process Manager (Low SK)
99
.32
99
.39
99.3
5
99
.35
99
.38
99
.35
99
.37
99
.44
99
.37
99
.36
99
.44
99
.38
99
.35
97
98
99
100
15 16 17 18 19 20 21 22 23 24 25 26 27
99.8%
Target
CW
Yie
ld %
Historical Data of Overall YIELD at TRIM & FORM Process
Yield
Yield Losses
0.63%
Yield Average: 99.37%
Average BTG Losses: 0.59%
Page
Why Project was Selected~ Breakdown Yields Losses ~
CRITERIA 1.1: INTRODUCTION OF PROBLEM
14
0
5
10
15
20
25
30
35
Rocker Arm Forming Punch Forming Spring Forming Pusher Waste lead
Nu
mb
er
of
BT
G C
ases
100%
80%
88%
94%
97%
Data obtained from Process Engineer (Winnie Goh)
Verified data by Maintenance /Process Manager (Low SK)
FactorNo of Cases
No of Cases
(%)
CumulativeCumulative
(%)
Rocker Arm
Forming Punch
Forming Spring
Forming Pusher
Waste Lead
Total
28 80 28 80
3 8 31 88
2 6 33 94
1 3 34 97
1 3 35 100
35 100 161
Page
Why Project was Selected~ Conclusion: Our Project Title ~
CRITERIA 1.1: INTRODUCTION OF PROBLEM
15
99.8%
= 0.43%99.8%
Yield
99.37%
0.59%
0.16%
Reduction:
0.43%
BTG Reject
Yield Improvement by Reducing Body to Ground (BTG) Reject at
Trim & Form Process from
0.59% to 0.16%
99.37%-
Page
Yield is defined as the quantity of good entities that have completed oneor more production steps in relation to the total quantity that has beenentered. Yield is reported in percent.
Project Terminologies ~ Definition of Yield ~
CRITERIA 1.1: INTRODUCTION OF PROBLEM
16
Quantity Out
Quantity In
___________= X 100%
Calculation
HOW to calculate Yield ?
Page
~ Our Process Flow ~
CRITERIA 1.1: INTRODUCTION OF PROBLEM
17
FRONT OF LINE
(FOL)
END OF LINE
(EOL)
TESTING
• Moulding• Deflashing• Solder Plating
• 100% Visual Inspection(EAV)
• Testing• Q Final Clearance
•Die Bond•2nd Die Bond•1st Wire Bond•2nd Wire Bond •100% Fav
• Trim & Form
Page
~ Our Nature of Work – Trim & Form Process ~
CRITERIA 1.1: INTRODUCTION OF PROBLEM
18
Page
~ Our Nature of Work – Typical Trim & Form Process ~
CRITERIA 1.1: INTRODUCTION OF PROBLEM
19
OFFLOADER MODULE
OPERATOR need to
transfer tube from Off
Loader Station to toot
box after completed the
lot
ONLOADER MODULE
TECHNICIAN needs to
ensure On Load Station
are in a good condition
PRESS MODULE
TECHNICIAN needs to
check Press Station and
tool during JHAM
Page
~ Our Nature of Work – Typical Trim & Form Process ~
CRITERIA 1.1: INTRODUCTION OF PROBLEM
20
First Lead Length Cut
Tie Bar Cut
Center Lead CutFormingFinal Lead Length Cut Heat Sink Cut
Page
Project Terminologies ~ Definition of Body to Ground (BTG) ~
CRITERIA 1.1: INTRODUCTION OF PROBLEM
21
BTG
Body to Ground (BTG) is the distance between back heatsink and lead tip(landing area),control limit spec for Body to Ground (BTG) is 40µm to120µm.
GOOD BTG Failure
40µm – 120µm
Page
How the project aligns with organization’s~ Aligned with Departmental Target ~
CRITERIA 1.2: INTRODUCTION OF PROBLEM
22
Business Year 2015
~ Focus on Cost ~
Key Results Area
MeasurementDepartmental
TargetTeam Target
Before Improvement
Quality Customer Complaint 0 0 0
Cost Yield 99.8% 99.8% 99.37%
DeliveryDelivery / week
(qty)22M 22M 22.5M
Morale Attendance 95% 95% 98.5%
Safety Severity Accident 0 cases 0 cases 0 cases
Page
How the project aligns with organization’s~ Aligned with Vision & Mission Company ~
CRITERIA 1.2: INTRODUCTION OF PROBLEM
Vision
The #OneBackEnd Manufacturing
and Competence Centre
MissionMaking MAL‘s
People Excellence Our Prime Leading Edge
the most responsive partner
to improve
our customer‘s competitiveness
Trust and respect others
Be passionate about profit
Focus on the
customer
Drive value through
innovation
Be ambitious
and manage risk
Strive for excellence
Team up for best
results
Foster your talents
High Performance
Behavior Model
23
Page
How the project aligns with organization’s~ Explanation of Target Setting Using SMART Concept ~
CRITERIA 1.2: INTRODUCTION OF PROBLEM
24
pecific
&
easurable
chievable
ealistic
ime
At Trim & Form Fico machine
Improve Trim & Form Yield Losses from 99.37% to 99.8%
Key wordConcept
Reduce Body to Ground (BTG) reject from 0.59% to 0.16%
By CW 53, Dec 2015 (6 Months)
Page
Potential Impact of the Project~ Unhappy Stakeholder ~
CRITERIA 1.3: INTRODUCTION OF PROBLEM
25
Impact
of Yield Losses
Customer Management Employee
KEY STAKEHOLDERS
YieldTarget : 99.8%To date : 99.37%
Cost
97
97.5
98
98.5
99
99.5
100
15 16 17 18 19 20 21 22 23 24 25 26
CW
YIE
LD
(%
)
Page
BTG Failure
Potential Impact of the Project~ Unhappy Stakeholder ~
CRITERIA 1.3: INTRODUCTION OF PROBLEM
26
IMPACT AND EFFECT
Ho
w it
Im
pact?
Key S
takeh
old
ers
Missed delivery commitmentCustomer
Quality Issue
BTG Reject
Management
Yield not
achieve targetUnit Failure
Page
Potential Impact of the Project~ Positive and Negative Impact of Stakeholder ~
CRITERIA 1.3: INTRODUCTION OF PROBLEM
27
IMPACT SCALE:
Category Stakeholder DescriptionPositive Impact
With Project
Completion
Negative Impact
Without Project
Completion
Degree
Of
Impact
Employee Trim & Form
Internal Customer,
Operates Machine &
Delivery
Achieve yield
target
No stoppages
Machine
downtime
Yield not achieve
High
(Direct)
Internal
Customer
EAV
Operates Machines,
Produce Delivery &
Output
Reduce downtime Line down
Higher downtime
High
(Direct)
Management
Plan, Manage
Production &
Delivery
Delivery high
Fast cycle time
Customer
Complain
Scrap Cost
High
(Direct)
CustomerEnd
Customer
Manufacturer of
automotive industry
Zero customer
complaint
Loss of Business
Bad company
image
High
(Direct)
End User Consumer Product user
Consumer
satisfaction
Safety of user
Delay received
product
Lose of Trust
High
(Direct)
TY
PE
IN
TE
RN
AL
EX
TE
RN
AL
PagePage 28
Page
How final solution was determined~ Brainstorming to Identify Potential Causes ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
29
ENVIROMENT
Low Yield
at Trim &
Form
Process
ROCKER ARM
INSUFFICIENT SKILL
PLATING THICKNESS
PREVENTIVE MAINTENANC
E (PM)
NOT FOLLOW SETUP
PROCEDURE
LEAD FRAME
PROBLEM
QUALITY CHECK
TRACK WORN OUT
AIR COMPRESSOR BREAKDOWN
OFF LOADER JAMMING
CONVERT DIE-SET
NO RESPONSIBILITY
SKIP PROCEDURE
WASTE LEAD
STUCK
POWER INTERRUPTION
NO AIR SUPPLY
LEAD FRAME HARDNESS
INDEXING PROBLEM
MIS-ALIGNMENT
NO ELECTRICAL SUPPLY
OCCASIONALLY INDEXER JAMMING
NOT USING PROPER TOOL
WARP FRAME
JHAM ACTIVITIES
NO VACUUM SUPPLY
NOT FOLLOW PROCEDURE
POOR TECHNICAL KNOWLEDGE SCREW NOT TIGHTEN
PROPERLY
NO PROPER
TRAINING
NOT FOLLOWING SET-UP PROCEDURE
MIS-HANDLING
POOR QUALITY CONTROL
NEW EMPLOYEE
FORMING PUNCH’S SPRING
BROKEN
PUSH PIN JAMMED
36Potential causes been selected from monitoring by using checksheet data
and validation from proses engineer
Page
How final solution was determined~ Brainstorming to Identify Potential Causes ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
30
ENVIROMENT
Low Yield
at Trim &
Form
Process
ROCKER ARM
INSUFFICIENT SKILL
PLATING THICKNESS
PREVENTIVE MAINTENANC
E (PM)
NOT FOLLOW SETUP
PROCEDURE
LEAD FRAME
PROBLEM
QUALITY CHECK
TRACK WORN OUT
AIR COMPRESSOR BREAKDOWN
OFF LOADER JAMMING
CONVERT DIE-SET
NO RESPONSIBILITY
SKIP PROCEDURE
WASTE LEAD
STUCK
POWER INTERRUPTION
NO AIR SUPPLY
LEAD FRAME HARDNESS
INDEXING PROBLEM
MIS-ALIGNMENT
NO ELECTRICAL SUPPLY
OCCASIONALLY INDEXER JAMMING
NOT USING PROPER TOOL
WARP FRAME
JHAM ACTIVITIES
NO VACUUM SUPPLY
NOT FOLLOW PROCEDURE
POOR TECHNICAL KNOWLEDGE SCREW NOT TIGHTEN
PROPERLY
NO PROPER
TRAINING
NOT FOLLOWING SET-UP PROCEDURE
MIS-HANDLING
POOR QUALITY CONTROL
NEW EMPLOYEE
FORMING PUNCH’S SPRING
BROKEN
PUSH PIN JAMMED
PREVENTIVE MAINTENANCE
(PM)
ROCKER ARM
INSUFFICIENT SKILL
PLATING THICKNESS
NOT FOLLOW SETUP
PROCEDURE
LEAD FRAME
PROBLEM
QUALITY CHECK
CONVERT DIE-SET
POWER INTERRUPTION
NO AIR SUPPLY
LEAD FRAME HARDNESS
JHAM ACTIVITIES
NO VACUUM SUPPLY
PUSH PIN JAMMED
Potential causes were generated during the brainstorming
session with the team members14
Page
How final solution was determined~ Using Cause and Effect Diagram ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
31
Low Yield at
Trim & Form Process
PLATING THICKNESS
LEAD FRAME PROBLEM
JHAM ACTIVITIES
NOT FOLLOW SETUP
PROCEDURE
POWER
INTERRUPTION
NO AIR SUPPLYNO VACUUM SUPPLY
INSUFFICIENT
SKILL
QUALITY CHECK
PREVENTIVE
MAINTENANCE (PM)
LEAD FRAME
HARDNESS
No electrical supply
Engine vacuum leak
Interruption from TNB
supply or plant facility
Interruption at plant
facility equipment
Interruption at plant
facility equipment
Air compressor
break down
Not done properly
Not follow
procedure
Skip task
Not follow procedure
Roller design
Non-durable
material (copper)
Push pin rusty
Reach
limit
New employee
Not perform
Solder
thickness out
of spec
Bent frame
Incoming frame
from supplier
Skip procedure
No proper training
Incoming
process
New employee
CONVERT DIE-SET
misalignment
Insufficient skill
Incoming from
subcon plating
PUSH PIN JAMMED
MAN MACHINE METHOD
MATERIALMATERIALENVIRONMENTENVIRONMENT
ROCKER ARM
ROLLER
WORN-OUT
Page
How final solution was determinedSummary of Brainstorming to Identify Most Potential Causes
~ Using Tree Diagram ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
Tree Diagram :~ Summary Verification of Potential Root Cause ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
36
Cons.CATEGORYCAUSES POTENTIAL CAUSES FINDING
Page
Rust & dust cause the forming punch not fully push to the
bottom position due to push pin jammed
FUNCTION Push pin is used to move the
rocker arm during the forming process
is carried out
MATERIAL Steel (K110)
First Selected Potential Root Cause~ Explanation on How Push Pin Causing BTG ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
37
Page
First Selected Potential Root Cause~ Explanation on How Push Pin Causing BTG ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
38
Page
First Selected Potential Root Cause~ Explanation on How Push Pin Causing BTG ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
39
.
.
.
.
.
.
.
.
.
.
Page
Prevent Push Pin from jamming due to dust & rusty
Suggestion and Implementation for Preliminary Action ~ Using 5W 1H ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
40
WHAT WHYWHY WHEREWHERE WHENWHEN WHOWHO HOWHOW
Page
BTG Failure
Prevent Push Pin from jamming due to dust & rusty To reduce reject Body to ground
Suggestion and Implementation for Preliminary Action ~ Using 5W 1H ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
41
WHATWHAT WHY WHEREWHERE WHENWHEN WHOWHO HOWHOW
Page
BTG Failure
Prevent Push Pin from jamming due to dust & rusty To reduce reject Body to groundTrim & Form Fico machine
Suggestion and Implementation for Preliminary Action ~ Using 5W 1H ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
42
WHATWHAT WHYWHY WHERE WHENWHEN WHOWHO HOWHOW
Page
BTG Failure
Prevent Push Pin from jamming due to dust & rusty To reduce reject Body to groundTrim & Form Fico machineDuring JHAM activity
Suggestion and Implementation for Preliminary Action ~ Using 5W 1H ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
43
WHATWHAT WHYWHY WHEREWHERE WHEN WHOWHO HOWHOW
Page
BTG Failure
Prevent Push Pin from jamming due to dust & rusty To reduce reject Body to groundTrim & Form Fico machineDuring JHAM activityShift maintenance
Suggestion and Implementation for Preliminary Action ~ Using 5W 1H ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
44
WHATWHAT WHYWHY WHEREWHERE WHENWHEN WHO HOWHOW
Page
BTG Failure
Prevent Push Pin from jamming due to dust & rusty To reduce reject Body to groundTrim & Form Fico machineDuring JHAM activityShift maintenanceUpdate JHAM from weekly to every shift
Suggestion and Implementation for Preliminary Action ~ Using 5W 1H ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
45
WHATWHAT WHYWHY WHEREWHERE WHENWHEN WHOWHO HOW
Page
First Selected Potential Root Cause~ JHAM Update ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
46
JHAM is a maintenance strategy wherein a schedule machine maintenance is carried out in short
period of production time which includes cleaning and inspection and performed by machine owner or technician.
JHAM include in schedule downtime. JHAM is perform according to panned maintenance schedule.
JHAM activities in Trim & Form area are done:
1. Shiftly (STS & RTR)
2. Weekly (STS only)
JHAM – Jishu Hozen Autonomous Maintenance
Page
First Selected Potential Root Cause~ Weekly to Shiftly inserted in JHAM ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
47
AFTERBEFORE
Page
Rocker Arm is used to move the forming punch during the lead formation
Steel
RM 950
FUNCTION
MATERIAL
COST PER PIECE
MACHINE
Buy-off check sheet filled
every conversion
Re-certification done every 2
years for machine owner
FALSEMANNot proper setup during tool
conversion
TRUE
TRUE
FALSE
FALSEMATERIAL
FALSEMETHOD
Cleaning and service done
only once per weekHaving dust and rusty.
Bush design easily worn-out
due to use non-durable
material (copper).
Heavy force on roller during
tool clamp.
Rarely happen base on
monitoring record.
Solder thickness out of spec
due to insufficient plating.
Frame are checked by 100%
VI operator and hold under
Engineer verification.
Lead frame already damage
from incoming process.
Machine only will be release
after PC Buy-Off and
Engineer Verification.
Skip task and not proper PM.
Why Low
YIELD at
Trim &
Form
Process
Second Selected Potential Root Cause~ Rocker Arm Definition & Description ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
48
Cons.CATEGORYCAUSES POTENTIAL CAUSES FINDING
MACHINE TRUECleaning and service done
only once per weekObserve dust and rusty.
Page
Rocker Arm is used to move the forming punch during the lead formation
Steel
RM 950
FUNCTION
MATERIAL
COST PER PIECE
Second Selected Potential Root Cause~ Rocker Arm Definition & Description ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
49
Page
Second Selected Potential Root Cause~ Explanation on How Roller Causing BTG ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
50
Problem area
Page
Suggestion and Implementation for Preliminary Action ~ Using Why Why Analysis ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
51
Because used poor material life span.
Why rocker arm roller worn out during forming?
Because rocker arm roller worn out during forming.
Why forming punch not fully in top position?
Because forming punch not fully in top position.
Why rocker arm cause Body to Ground reject?
To change different material for rocker arm roller.
Page
Result of Preliminary Action~ Using 5W 1H ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
52
What is the proposal? Why need to modify it ? Where is the changes?
When is idea raise? Who propose this idea? How?
To find better material for rocker arm roller
To reduce Body to Ground (BTG) reject
At Trim & Form Fico Machine
During brainstorming session
All Warriors member
Further study by using 4R and WHY WHYAnalysis
To change different material for rocker arm roller.
Page
ReviseTo have more frequent
check
Revision on work
procedure
To ensure the rocker arm is
in good condition
ReplaceTo ensure rocker arm
in accurate position
Change from copper
bushing to solid type
rocker arm roller
To have long life span
and more reliable design
RearrangeTo stabilize forming
punch
Shorten distance between
rocker arm holder and
forming punch
To ensure forming
punch reach at top
position
RedesignTo ensure forming
punch fully press
to top position
Modify rocker arm
roller to fit type design
To stabilize forming
punch
Further Brainstorm to Identify Various Potential CreativeandInnovative Solution ~ Using 4R and Why Why Analysis ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
53
Potential
SolutionWhy ? Why ? Conclusion
Page
Evaluating the Advantages & Disadvantages of VariousPotential Creative and Innovative Solution on 2 Measurable
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
54
Any quality risk? Quality
Cost Any cost involve?
Quality
Cost
Criteria Team DecisionMeasurable
Page
Evaluating Various Potential Creative and Innovative Solution ~ Advantages & Disadvantages of 4R ~
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
55
No quality risk
- High cost needed (RM1800)
- Need to change whole rocker
arm.
NA- Involved supplier to redesign the
dieset structure
Low Risk
- Robust material to increase life
span
- Low cost (RM 60)
No quality risk- Limited space for check sheet
storage.
Redesign- Modify rocker
arm roller to fit
type design
Rearrange- Shorten distance
between rocker
arm holder and
forming punch
Replace - Change from
copper bushing
to solid type
rocker arm
roller
Revise- Review on
work
procedure
Team Decision Based on
QUALITY &Creative
Technique
Measurable Team
Decision
√
X
X
X
COST
Steel with copper type
bushing
Solid steel type
Page
Systematic Assessment for Final Creative and InnovativeSolution Against Targeted Objectives
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
56
Collaborate with supplier to fabricate solid rocker arm roller
Phase 2
Collaborate with production to implement machine fortrial run
Phase 3
Data collection and monitoring.Phase 4
Phase 1Consult & collaborate team’s proposal together with project facilitator (expert in tooling).
Replace - Replace new material for rocker arm roller
Page
Systematic Assessment for Final Creative and Innovative Solution Against Targeted Objectives – Step 1
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
57
Phase 1Consult & collaborate team’s proposal together with project facilitator (expert in tooling).
~ Design for rocker arm roller is drafted
by team members
~ Discussion with facilitator Tan Say Kee
Page
Systematic Assessment for Final Creative and Innovative Solution Against Targeted Objectives – Step 2
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
Phase 2Collaborate with supplier to fabricate solid rocker arm roller
1) Material
- Hardened steel
2) Strength
- Strong and robust connection
3) Made In
- Local
4) Price / RM
- RM60
O
P
T
I
O
N
2
1) Material
- Cast iron
2) Strength
- Weak and rusty
3) Made In
- Local
4) Price / RM
- RM40
O
P
T
I
O
N
1
Before
Design
After
Design
58
Page
Systematic Assessment for Final Creative and Innovative Solution Against Targeted Objectives – Step 2
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
Phase 2Collaborate with supplier to fabricate solid rocker arm roller
1) Material
- Hardened steel
2) Strength
- Strong and robust connection
3) Made In
- Local
4) Price / RM
- RM60
O
P
T
I
O
N
2
1) Material
- Cast iron
2) Strength
- Weak and rusty
3) Made In
- Local
4) Price / RM
- RM40
O
P
T
I
O
N
1
Before
Design
After
Design
59
Page
Systematic Assessment for Final Creative and Innovative Solution Against Targeted Objectives – Step 3
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
60
Selected 1 Machine :MTF001 (Poor machine-higher produce BTG reject)
Duration :CW 39 2015 to CW 42 2015 (4 Weeks)(OCT-2015)
Reason of choosing 4 weeks data monitoring :
Recommended by Engineer to ensure that :
Any data collection/monitoring must involve 3 shifts rotation (A B C)
To observe trend of trial run result
3 shifts are well briefed and followed the procedure/instruction of new implementation
Team is able to collect feedbacks for further improvement (if necessary)
Phase 3Collaborate with production to implement machine fortrial run
Page
Systematic Assessment for Final Creative and Innovative Solution Against Targeted Objectives – Step 4
CRITERIA 2.4: CREATIVE AND INNOVATIVE FINAL SOLUTIONS
