降低喷漆治具成本DMAIC

降低喷漆治具成本DMAICTeamIntroductionOpportunity/BusinessCase/ProjectScopeTargetSettingAndScheduleProjectImplementationAccomplishments/ResultsTeamMembers’OfContactInformationTableofContent2TeamIntroductionOpportunity/BusinessCase/ProjectScope

---Background---TheIntroductionOfPaintingProcess

---ProjectScopeTableofContent3Industrialpollutiondamagesourenvironmentsignificantly.Background4GreenhouseeffectIcebergsaredisappearing.

Penguinsarelookingforhome.“Iwanttogohome!”Daddy,whereisourhome?”“Idon’tknow”.Background5

Ourcommitmenttosupportingenvironmentalprotectionofair,water,land,wasteandnaturalresourcesis,andwillremain,apriorityforthiscompany.

EnvironmentalPolicy

Reducethepaints

wasteandmaterialwasteBackground6TheintroductionofpaintingprocessDuringproduction：sprayinggunsprayAfterproduction:disassemblyproductsandrecyclefixtureCausepaintswasteCausefixtures

wastePreparation:Assemblyofrawpartstofixtureraw-partPaintfixturefinishedpartsPaint

wasteusedfixtureOutputInput7PAINTSWASTEFIXTUREWASTENeedtorecycleAccordingtoenvironmentalimpactRPNevaluation,paintingfactoryconcludetoimprove:ProjectScopeNeedtoreduce8TeamIntroductionOpportunity/BusinessCase/ProjectScopeTargetSettingAndScheduleProjectImplementationAccomplishments/ResultsTeamMembers’ContactInformationTableofContent91.Reducetheemissionofpaintsby20%2.Improvefixturerecycletimesby50%BeforeAfterAimingforsavingofpaintusageofthegapbetweenthetwoparts.Increasefixturerecycleperiodfrom2timesto3times150mm30mm30mm/150mm=20%TargetSettingImprovement

After3X

Before2X

10planactual08-Aug08-Oct08-Nov08-Dec09-Jan09-FebItemScopeStatusOverviewRootCauseanalysisSolutionDatacollectionEfficiencyStandardizationPlanSchedule08-Sep11G-ray(RimBlackberry-8000)Nicole(SonyEricssonK530i)Jie

(SonyEricssonK630c)Aalto

(NokiaN95)

Meteor(RimBlackberry-9000)08-Oct08-Nov08-Dec09-Jan09-FebplanactualProjectSchedule08-SepProjectname12TeamIntroductionOpportunity/BusinessCase/ProjectScopeTargetSettingAndScheduleProjectImplementation---ReducePaintsWaste---FixtureRecycleTimesTableofContent13PaintsWasteManMethodEnvironmentMaterial

MachineNotfollowSOPInsufficienttrainingchangepaintsmixingratioWrongfixturedesignParameterisnotcorrectAirpipedropoff

ColorunstableRawpartscleanlinessCleanroomcleanlinessBoothpressuretoohighBoothTemperaturetoohighBoothHumidity(40%~70%)

1.1RootCauseAnalysisSpraypressuretoohighPaintingDirectionFixedFixturecleanlinessControlledWithoutcontrol1.

ReducePaintsWaste141.2StatusOverview1.

ReducePaintsWasteThefixedsprayinggunleadtopaintswastebetweentwospindlesSprayGunVideo=FixPaintingSprayGunCausePaintsWasteGap15

1.3Solution

RobotSpayPainting1.

ReducePaintsWasteRobotsprayguncanreducetheproblemofpaintswaste

VideoofPaintingrobotEachsprayguntrackasinglespindleandspray,whichwillsavepaintbetweentwoparts.16

1.4DataCollectionPartsQ’ty(PCs)BeforeImprovement(g/pcs)AfterImprovement(g/pcs)Improvement(Save)%TotalSave(g)PAINTSTHINNERPAINTSTHINNERPAINTSTHINNERPAINTSTHINNERR/H2445451.621.781.2961.42420%20%79219.587042.5B/D2094921.621.781.2961.42420%20%67832.274531.6Capbottom2124330.810.890.6480.7220%19%34408.836108.2Total666470//////181460197682Paintssave20%PaintsreduceinSep.TaketheGAMMA-RAYasanexle1.

ReducePaintsWaste171.

ReducePaintsWasteGAMMA-RAYR/HB/D&BOTTOM20%GAMMA-RAYR/HGAMMA-RAYB/DGAMMA-RAYBOTTOM1.4Data

CollectionPaintsreduceinSep.unit:g/pcs18Quality?1.

ReducePaintsWaste19Yieldratecomparisonbetweenrobotandfixedgun1.5QualityConfirmationGAMMA-RAY

robotpaintingyieldrateinSepvsfixedpaintinginAug.1.

ReducePaintsWasteVerycloseyieldrate!201.

ReducePaintsWaste

ContinuousImprovementAndUpdatingBOM

UpdatingBOM:Paints:from1.62g/pcsto1.296g/pcsThinner:from1.78g/pcsto1.424g/pcs

21

Statisticallywereducedpaintswastewithrobotsprayguntoreachourtarget,whilemaintaining

goodproductqualityatthesametime

.Nextwewill

introducehowtoimprovethefixturerecycletimes.1.

ReducePaintsWaste222.1StatusOverview2.FixtureRecycleTimesFixtureQuantity(A)94021pcsAssembledQuantity(perfixture)(B)26pcsPaintedQuantity(C)4889092pcsRecycleTimes(D)

A*BC

D==2Aug-2008G-ray’sData

Lessfixturerecycletimesresultedlargequantityfixturewaste23MachineManMethodsEnvironmentMaterialInsufficientRecycleTimesTheamountoffixtureexhaustisbigUnitfixtureproductioncapacityislowerLessfixtureprojectsThefixturemachineiswellcontrolledFixturesurfaceisdirtyStorageenvironmentisdirtyFixturesupplierqualitycontrolisnotwellWithoutthedeclareofreducingthecostThelowerconsciousofreducingfixturecostFitsituationisnotwellOperationmethodnotwelltoknowFixturedesignisun-suitableHardtoassemblethefixtureThefixturefeestakeabout70%

FixtureWasteBelackofeducation2.2RootCauseAnalysis

2.FixtureRecycleTimesControlledWithoutControl242.3Solution2.

Fixture

RecycleTimes★

Testfixturemaximumrecycletimes★Fixtures'reworkDecreasefixtureusagequantityEliminationofexhaustemissionIncreasefixturecycletimes？？？25

2.3.1TestTheMaximumRecycleTimesOfFixtures2.

FixtureRecycleTimes1.3G-rayVolumeKeyBottomCoverTestInSep.2008Scrap%QualitycontrastTimesDefectParticleFiberCoveringPaintpeelOrangepeelGreasePoorCoverageTotal2th1.90.60.20.200.10.13.13th1.90.70.10.20.10.10.13.24th1.80.70.30.20.10.10.13.35th1.90.60.30.30.10.103.36th2.10.70.41.3

0.30.20.15.17th4.10.51.22.40.20.30.19.326

2.3.2Fixtures'ReworkBefore–WithoutStickerAfter–WithStickerAddstickerontheholeExle:G-rayVolumeKeyBottomBoardFixture2.

Fixture

RecycleTimes

Simplereworklikeaddingstickeruponthefixtureswillextendthemaximumrecycletimes.272.3.2.Fixtures’ReworkG-rayVolumeKeyBottomCoverInSep.2008Scrap%2.

Fixture

RecycleTimesQualitycontrastTimesDefectParticleFiberCoveringPaintpeelOrangepeelGreasePoorCoverageTotal5th1.80.70.30.20.10.10.13.36th1.90.60.30.30.10.20.13.47th2.20.81.20.40.30.40.35.68th2.81.13.61.20.20.30.39.528TheresultsoftheGMMA-RAYfixtureimprovement

Paintedquantity(10k)Recycletimes(2)*Assembledquantity(26pcs)=

193fixtures*Weight(0.0202kg)=3.8986kg10KproductionofVolumeKeyBottomCoverasanexleRecycletimes(6)*Assembledquantity(26pcs)=65fixtures

*Weight(0.0202kg)=1.3130kg

Paintedquantity(10k)VSReduce2.5856kg/10KIncreaserate66.3%reachouraimedtarget(Before)(After)2.

Fixture

RecycleTimes66.3%29StandardizeinWI2.

Fixture

RecycleTimes30TeamIntroductionOpportunity/BusinessCase/ProjectScopeTargetSettingAndScheduleProjectImplementationAccomplishments/ResultsTeamMembers’ContactInformationTableofContent31Moreprojectsareapplyingtheabove-mentionedimprovementwithdifferentaccomplishments.Accomplishments/Results32PartPAINTSFIXTUREBefore(kg)After(kg)DecreasePercentBefore(pcs)After(pcs)DecreasePercentBlackberry80005548443820%67171926861766%Blackberry90003460198443%1062893542966%K530i6508493724%827475516533%K630i111779628%11944597250%N9510698