Download - QCC theme on part reject reduction
LEADERNG SWEE CHER
(SUPERVISOR)
MEMBERFAUZIAH
(LEADER JUNBILINE)
MEMBERLEE YOKE WAH
(LEADER MAINLINE)
MEMBERAZHANI
(LEADER MANUALLINE)
MEMBERNORFAEZAH
(LEADER CALENDAR LINE)
SUB LEADERROZIDAH
(LEADER KENSALINE)
MEMBERMOHD SAKRI
(SENIOR
TECHNICIAN)
MEMBERMOHD NASAHA
(SENIOR TECHNICIAN)
Why?2nd Highest F-cost in Assembly.Future plan of first QC project.
Top Reject in Assembly.
1# UKE
1# UKE REJECT REDUCTION
C rys talT o R educ e C os t of 1# Uke R ejec t P art T o R educ e 1# Uke R ejec t R ate
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4P lanAc tualP lanAc tualP lanAc tualP lanAc tualP lanAc tualP lanAc tualP lanAc tualP lanAc tualP lanAc tualP lanAc tualP lanAc tual
AC T ION
F ull Implementation
DOS olution Implementation
AL L
C HE C K R es ult Monitoring
S tandardization AL L
F uture P lan AL L
S ep-14
P roblem Analys is AL L
AL L
P ICAC T ION IT E M
AL L
P roblem Verific ation AL L
R ec ommend Ac tion for Improvement
AL L
Nov-14 Dec -14
P L AN
T heme S elec tion AL L
Data C ollec tion AL L
T arg et S etting AL L
Oc t-14Aug -14
T heme:Apr-14 May-14 J un-14J an-14 F eb-14 Mar-14 J ul-14
C irc le Name:Objec tive:
Legend: Plan
Actual
Pareto Diagram for 1# UKE REJECT (Before)
0.27%
0.02% 0.02% 0.01%
0.06%
858277
71
0.00%
0.05%
0.10%
0.15%
0.20%
0.25%
0.30%
0.35%
Tai Kizu Tai dirty / stain Tai dent Tai bend Others
Reject Rate
0
20
40
60
80
100Percentage (%)
1# UKE(Data of Jan’14 to Jun’14)
Pareto Diagram for 1# UKE REJECT (Before)
0.27%
0.02% 0.02% 0.01%
0.06%
7177
8285
0.00%
0.05%
0.10%
0.15%
0.20%
0.25%
0.30%
0.35%
Tai Kizu Tai dirty / stain Tai dent Tai bend Others
Reject Rate
0
20
40
60
80
100Percentage (%)
Tai Kizu
(Data of Jan’14 to Jun’14)
START
Dashinki Kumi Process
END
Jiita Junbi Process
Tsutsukana Junbi Process
1# Uke Junbi Process
Zara-Omotte Process
Zara-Ura Process
Tenpu Junbi Process
Furitsuke Process
Hodo Chosei Process
Jido Maki Kumi Process
Karenada Kumi Process
Higuruma Osae Junbi Process
Koteinai Kensa Process
Chuck dirty
Stopper spoil
METHOD
MACHINE
MAN
MATERIAL
No guide line for pincer condition
1# Uke Reject
1# Uke Bowl Jam
Neji P&P unit badset
Stocker jam
1# Uke pick up with spoil pincers
1# Uke Tray jam
Loosen Neji slippery
1# Uke P&P unit mis-chuck
Screw driver holding not straight
1# Uke Hanten unit P&P failure
2# Tsutae Guruma setting unit's failure
Driver cap wear off
Driver tip wear off
1# Uke unable to set evenly
on Jiita
Lack of skill
Sensor dirty
Air cylinder spoil
1# Uke out of position
1# Uke tray spoil
Solenoid dirty
Tsume Reba Opener too low
Part drop to conveyor
Tsume Reba Opener no proper jig
Air cylinder
spoil
Conveyor speed inconsistence
KTS position checker
malfunction
Vibration strong
Air pressure insufficient
Vacuum inconsistence
Pallet spoil
Turning bar too long
Mov't float
1# Uke Sori
1# Uke CD out
Incoming part spoil
Part easy Kizu
Lack of practice
OJT not thorough Judgment error
New manpower
Not follow instruction
Stubborn
Not sufficient guidance
Shortage of chance to
perform OT
Stress on working environment
Indirect work is relatively high
Careless
Not healthy
Not sufficient
Tired in routine work
Manpower shortage
Communication breakdown
Foreign worker
Language barrier
Vacuum
weak
Life span over
Driver cap dirty
Kobako mis-Winding
Jig design weakness
Stopper spoil
Sensor malfunctionSensor spoilSensor dirty
Stopper JamScrew driver size incorrect
MANMAN
METHODMETHOD
MACHINEMACHINE
MATERIALMATERIAL
Factor Problem Verification Result Comment PICNot sufficient guidance O New manpower is guide by operator Ng SC
Judgment error O Inspector miss-judge the 1# Uke Rozidah
Language barrier O Foreign worker unable to well understand Malay language Sakri
Tired in routine work O Part frequently got various reject Nasaha
Tsume Reba Opener no proper jig O The jig is handmade by line technician Fauziah
Vacuum inconsistence O Vacuum supply is variance from -54 to -45 Cm Hg. Lee YW
Chuck dirty O 1# Uke pick up chuck is dirty & oily Azhani
Conveyor speed inconsistence O The speed controller or conveyor is unable to lock Norfaezah
Driver cap wear off O Driver cap wear off & cause 1# Uke Kizu Ng SC
Driver tip wear off O Driver tip wear off & cause 1# Uke Kizu Rozidah
Pallet spoil O Spoil pallet cause the Hanten unit miss-chucking & part drop Sakri
Stopper spoil O Spoil stopper unable to proper lock the pallet Nasaha
Air cylinder spoil O Spoil air cylinder cause the tray jam Fauziah
Vibration strong O The vibration of PF bowl is inverse proportion to part quantity Lee YW
Screw driver size incorrect O Incorrect screw driver size is causing 1# Uke Kizu during dismantle Neji Azhani
No guide line for pincer condition O Operator is not aware the pincer can cause the 1# Uke spoil Norfaezah
1# Uke Sori O 1# Uke easily drop from mov't if Sori Ng SC
Part easy Kizu O The part is Kizu during the mov't assemble process Rozidah
Man
Machine
Method
Material
Criteria: Urgent, Cost and Ability
1 Not sufficient guidance 1 Line Leader to fully guide the new manpower
2 Display picture of Good & No Good part
3 Establish sample of reject
3 Language barrier 4 Teach with picture to explanation the job
4 Tired in routine work 5 Simplified the inspection job
5 Tsume Reba Opener no proper jig 6 Bench mark a standard jig
6 Vacuum inconsistence 7 Install vacuum regulator
7 Chuck dirty 8 Weekly inspection & clean of chuck
8 Conveyor speed inconsistence 9 Improvement on conveyor system
9 Driver cap wear off 10 Weekly inspection & clean of driver cap
10 Driver tip wear off 11 Weekly inspection & clean of driver tip
11 Pallet spoil 12 Replace with new pallet
12 Stopper spoil 13 Periodical change the stopper
13 Air cylinder spoil (for 1# Uke tray) 14 Inspection & replace new air cylinder once tray jam
14 Vibration strong 15 Set the guide line of feed the part to the PF bowl
15 Screw driver size incorrect 16 Standard the size of screw driver
16 No guide line for pincer condition 17 Set the guide line of good pincer condition
17 1# Uke Sori 18 Install guide during 1# Uke setting
18 Part easy Kizu 19 Use specify pincer to handle the part
Judgment error2
S/N Problem Selected Propose SolutionS/N
1 Line Leader to fully guide the new manpower Fauziah 01-05-14
2 Display picture of Good & No Good part Lee YW 01-05-14
3 Establish sample of reject Rozidah 01-05-14
4 Teach with picture to explanation the job Fauziah 01-05-14
5 Simplified the inspection job Azhani 01-07-14
6 Bench mark a standard jig Nasaha 01-07-14
7 Install vacuum regulator Sakri 01-07-14
8 Weekly inspection & clean of chuck Norfaezah 01-06-14
9 Improvement on conveyor system Ng SC PENDING10 Weekly inspection & clean of driver cap Lee YW 01-06-14
11 Weekly inspection & clean of driver tip Sakri 01-06-14
12 Replace with new pallet Ng SC 01-06-14
13 Periodical change the stopper Sakri 01-07-14
14 Inspection & replace new air cylinder once tray jam Nasaha PENDING15 Set the guide line of feed the part to the PF bowl Fauziah 01-07-14
16 Standard the size of screw driver Rozidah 01-06-14
17 Set the guide line of good pincer condition Azhani 01-07-14
18 Install guide during 1# Uke setting Sakri 01-07-14
19 Use specify pincer to handle the part Azhani 01-07-14
IMPROVEMENT ACTIVITIES PIC IMPLEMENT DATE
TRY SOLUTIONEstablish Reject
Sample1
MISS - JUDGE
To review inspectors judgment on appearance defect
TRY SOLUTIONInstall Standard Jig for Tsume Reba
Opener2
OLD TYPE
NEW TYPE
TSUME REBA OPENER
KENPAI REJECT REDUCE FROM 4.71% to 3.02%
To Improve 2# Tsutae Guruma Part Setting
3
TRY SOLUTIONInstall Vacuum Regulator at FA Junbi
Line
VACUUM REGULATORVACUUM REGULATOR
GUIDE LINE
VACUUM SENSOR ERROR REDUCE
To improve and stabilize vacuum pressure
TRY SOLUTIONChange New Pallet for I#
Uke Junbi machine4
KENPAI REJECT REDUCE FROM 3.23 % to 2.02%
To improve 1# Uke part Setting
TRY SOLUTIONChange Stopper at Kobako Winding
process5
Scratches Cause By Winding Reduce
To improve Pallet Locating
TRY SOLUTIONSet guideline at Part
Feeder Controller6
GUIDE LINE
PART JAM AT BOWL REDUCE FROM 9 TIMES TO 1 TIME PER DAY
To stabilize 1# Uke Part Feeder Vibration
TRY SOLUTION7 Improve Screw Driver for
repair
1# UKE NEJI
Scratches due to Screw Driver Reduce from 42 pcs to 4 pcs per month
Use screw driver tip Ø1.4mm
TRY SOLUTION
HAND STOPPER
8
To prevent 1# Uke drop during Kamiawase process
Install Hand Stopper at Yudo Maruana Kamiawase Unit
TRY SOLUTION Improve Pincer Condition9
TIP ROUNDED
SHARP TIP
Scratches due to Pincer reduce from 21 pcs to 1 pc per month
Pareto Diagram for 1# UKE REJECT (Before)
0.27%
0.02% 0.02% 0.01%
0.06%
8582
7771
0.00%
0.05%
0.10%
0.15%
0.20%
0.25%
0.30%
0.35%
Tai Kizu Tai dirty / stain Tai dent Tai bend Others
Reject Rate
0
20
40
60
80
100Percentage (%)
Pareto Diagram for 1# UKE REJECT (After)
0.09%
0.01% 0.00% 0.01%
0
918881
0.00%
0.05%
0.10%
0.15%
0.20%
0.25%
0.30%
0.35%
Tai Kizu Tai dent Tai bend Others
Reject Rate
0
50
100
150
200
250
300
350Percentage (%)
1# Uke Reject %
71% REDUCTION
(Data of Jan’14 to Jun’14) (Data of Aug’14 to Dec’14)
REJECT REDUCE FROM 0.38% TO 0.11%
ITEMS MONTHLY YEARLY
1) REJECT COST (US$) USD 280 USD 3,357
2) REPAIR COST ($4.8/Hour) USD 273 USD 3,272
3) MANPOWER COST (US$) USD 249 USD 2,982
Copy Document No : WI - AS2 - 06
No Rev. No : 1
1# UKE PREPARATION PROCESS Date : 02-01-15
(FA 1# UKE JUNBI) Page No. : 1 of 1
Station
JA1F Set 1# Uke onto pallet. 1# Uke Setting condition.
1# Uke General appearance.
J1F Set Yudo Maru Ana Bane (Not for Cal 7S) Yudo Maru Ana Bane Setting condition
Position Yudo Maru Ana Bane (Not for Cal 7S) Yudo Maru Ana Bane General appearance
Set 3# Cap Jewel 3# Cap Jewel Upside down
Set 3# Osae Jewel 3# Osae Jewel Position
J2F Set 5# Cap Jewel 5# Cap Jewel Upside down
Set 5# Osae Jewel 5# Osae Jewel Position
J2B Set 1# Tsutae Guruma onto pallet 1# Tsutae Guruma Setting condition
Oil 1# Tsutae Guruma Hen Shin (S4) Oiling Position & Volume as WS Drawing
Set Tsume Reba onto 1# Tsutae Guruma Tsume Reba fully set onto 1# Tsutae Guruma
Oil 1# Tsutae Guruma Shin (S4) Oiling Position & Volume as WS Drawing
J1B Turnover 1# Uke & Set to 1# Tsutae Guruma 1# Uke Setting condition.
Oil 5# Taishin Ana Jewel (MA) Oiling Position & Volume as WS Drawing
Set C-Ring onto 1# Tsutae Guruma 1# Tsutae Guruma Agaki Spec = 2.6 ~ 9.4 su.
Oil Yudo Maru Ana Guruma slot (Not for Cal 7S) Oiling Position & Volume as WS Drawing
JA1B Oil Maru Ana Guruma center surface (Not for Cal 7S) Oiling Position & Volume as WS Drawing
Set 1# Uke Shita Za (Not for Cal 7S) Proper Setting to 272# & 273# Pin
Set 1# Uke Shita Za Neji - 272# (Not for Cal 7S) Neji Torque = 17.5 ±7.5 Nmm
Oil 3# Taishin Ana Jewel (MA) Oiling Position & Volume as WS Drawing
JA1U Turnover 1# Uke & Set onto Tray Guide the 1# Uke Tray 1# & 62# Pin
Inspector Check Point
Check the 1# Uke Kizu with Z - Lamp During 1# Uke Omotte Turning Process
Kizu Limit judgment Refer to Pictures & Defectives sample
History : Prepared Approved
Rev 1: Add Inspection method
Fauziah Ng SC Normaya
Verified
INSTRUMENTS TECHNOLOGY (J) SDN. BHD.
WORK INSTRUCTION
TITLE :
TASK ELEMENT KEY POINT
21 Work Instruction of 1# Uke Preparation Process
(WI-AS2-06 Rev No: 1)
Work Instruction of Guidelines for Training New Manpower
(WI-AS2-042 Rev No: 0)Copy Document No : WI - AS2 - 42
No Rev. No : 0
TITLE : GUIDELINE FOR TRAINING NEW MANPOWER Date : 02/01/2015
Page No. : 1 of 1
S/No
1 Understand & Practice the Process Work Standard (WS) Explanation by Leader Level & above only.
2 Understand & Practice the Process Work Instruction (WI) Explanation by Leader Level & above only.
3 Understand & Practice the Process Control Standard (PCS) Explanation by Leader Level & above only.
4 Understand & Practice Assembly 2 Schedule Waste. Explanation by Leader Level & above only.
5 Understand & Practice Assembly Clean Room Rules Explanation by Leader Level & above only.
6 Read & Understand the Shop KPI (QCD report) Explanation by Leader Level & above only.
7 Understand the SH (Standard Hour) & AH (Actual Hour) Explanation by Leader Level & above only.
8 Daily Recording of Process Working Hours Leader to monitor the daily learning progress
9 Monthly summaries of Process Working Hours Leader to monitor the monthly learning progress
10 Proper operating procedure to Stereo Microscope Leader teaching by use WI no: WI-AS2-05
11 Proper practice on finger cot usage in Assembly production Leader teaching by use WI no: WI-AS1-60
to ensure the cleanliness of movement
12 Proper take care & periodically inspection on pincer. Leader to explain the care points of pincer
13 To report process abnormality to Leader immediately. Leader teaching by use WI no: WI-AS2-27
14 To raise question if any doubt Leader to act positively & encourage on
questions
History : Prepared Approved
Fauziah Ng SC Normaya
WORK INSTRUCTION
TASK ELEMENT KEY POINT
Verified
INSTRUMENTS TECHNOLOGY (J) SDN. BHD.
43 Weekly Machine Jig
Inspection Record Sheet
(No: ASSY 2 – 96a)
Monthly Machine Jig
Inspection Record Sheet
(ASSY 2 - 96b)
THANK YOU FOR YOUR ATTENTION! THANK YOU FOR YOUR ATTENTION!
ANY QUESTIONS?ANY QUESTIONS?