降低喷漆治具成本DMAIC.ppt

1,TeamIntroductionOpportunity/BusinessCase/ProjectScopeTargetSettingAndScheduleProjectImplementationAccomplishments/ResultsTeamMembersOfContactInformation,TableofContent,2,TeamIntroductionOpportunity/BusinessCase/ProjectScope-Background-TheIntroductionOfPaintingProcess-ProjectScope,TableofContent,3,Industrialpollutiondamagesourenvironmentsignificantly.,Background,4,GreenhouseeffectIcebergsaredisappearing.,Penguinsarelookingforhome.,Background,5,Ourcommitmenttosupportingenvironmentalprotectionofair,water,land,wasteandnaturalresourcesis,andwillremain,apriorityforthiscompany.EnvironmentalPolicy,Reducethepaintswasteandmaterialwaste,Background,6,Theintroductionofpaintingprocess,Duringproduction：sprayinggunspray,Afterproduction:disassemblyproductsandrecyclefixture,Causepaintswaste,Causefixtureswaste,Preparation:Assemblyofrawpartstofixture,raw-partPaintfixture,finishedpartsPaintwasteusedfixture,Output,Input,7,PAINTSWASTE,FIXTUREWASTE,Needtorecycle,AccordingtoenvironmentalimpactRPNevaluation,paintingfactoryconcludetoimprove:,ProjectScope,Needtoreduce,8,TeamIntroductionOpportunity/BusinessCase/ProjectScopeTargetSettingAndScheduleProjectImplementationAccomplishments/ResultsTeamMembersContactInformation,TableofContent,9,1.Reducetheemissionofpaintsby20%,2.Improvefixturerecycletimesby50%,Before,After,Aimingforsavingofpaintusageofthegapbetweenthetwoparts.,Increasefixturerecycleperiodfrom2timesto3times,30mm/150mm=20%,TargetSetting,10,plan,actual,08-Aug,08-Oct,08-Nov,08-Dec,09-Jan,09-Feb,Item,Scope,StatusOverview,RootCauseanalysis,Solution,Datacollection,Efficiency,Standardization,PlanSchedule,08-Sep,11,G-ray(RimBlackberry-8000),Nicole(SonyEricssonK530i),Jie(SonyEricssonK630c),Aalto(NokiaN95),Meteor(RimBlackberry-9000),08-Oct,08-Nov,08-Dec,09-Jan,09-Feb,plan,actual,ProjectSchedule,08-Sep,Projectname,12,TeamIntroductionOpportunity/BusinessCase/ProjectScopeTargetSettingAndScheduleProjectImplementation-ReducePaintsWaste-FixtureRecycleTimes,TableofContent,13,PaintsWaste,Man,Method,Environment,Material,Machine,NotfollowSOP,Insufficienttraining,changepaintsmixingratio,Wrongfixturedesign,Parameterisnotcorrect,Airpipedropoff,Colorunstable,Rawpartscleanliness,Cleanroomcleanliness,Boothpressuretoohigh,BoothTemperaturetoohigh,BoothHumidity(40%70%),1.1RootCauseAnalysis,Spraypressuretoohigh,PaintingDirectionFixed,Fixturecleanliness,ControlledWithoutcontrol,1.ReducePaintsWaste,14,1.2StatusOverview,1.ReducePaintsWaste,Thefixedsprayinggunleadtopaintswastebetweentwospindles,SprayGun,Video=FixPaintingSprayGun,CausePaintsWaste,Gap,15,1.3SolutionRobotSpayPainting,1.ReducePaintsWaste,Robotsprayguncanreducetheproblemofpaintswaste,VideoofPaintingrobot,Eachsprayguntrackasinglespindleandspray,whichwillsavepaintbetweentwoparts.,16,1.4DataCollection,Paintssave20%,PaintsreduceinSep.,TaketheGAMMA-RAYasanexample,1.ReducePaintsWaste,17,1.ReducePaintsWaste,GAMMA-RAYR/HB/D&BOTTOM,1.4DataCollection,18,Quality?,1.ReducePaintsWaste,19,Yieldratecomparisonbetweenrobotandfixedgun,1.5QualityConfirmation,GAMMA-RAYrobotpaintingyieldrateinSepvsfixedpaintinginAug.,1.ReducePaintsWaste,Verycloseyieldrate!,20,1.ReducePaintsWaste,ContinuousImprovementAndUpdatingBOM,UpdatingBOM:Paints:from1.62g/pcsto1.296g/pcsThinner:from1.78g/pcsto1.424g/pcs,21,Statisticallywereducedpaintswastewithrobotsprayguntoreachourtarget,whilemaintaininggoodproductqualityatthesametime.Nextwewillintroducehowtoimprovethefixturerecycletimes.,1.ReducePaintsWaste,22,2.1StatusOverview,2.FixtureRecycleTimes,Aug-2008G-raysData,Lessfixturerecycletimesresultedlargequantityfixturewaste,23,Machine,Man,Methods,Environment,Material,InsufficientRecycleTimes,Theamountoffixtureexhaustisbig,Unitfixtureproductioncapacityislower,Lessfixtureprojects,Thefixturemachineiswellcontrolled,Fixturesurfaceisdirty,Storageenvironmentisdirty,Fixturesupplierqualitycontrolisnotwell,Withoutthedeclareofreducingthecost,Thelowerconsciousofreducingfixturecost,Fitsituationisnotwell,Operationmethodnotwelltoknow,Fixturedesignisun-suitable,Hardtoassemblethefixture,Thefixturefeestakeabout70%,FixtureWaste,Belackofeducation,2.2RootCauseAnalysis,2.FixtureRecycleTimes,ControlledWithoutControl,24,2.3Solution,2.FixtureRecycleTimes,TestfixturemaximumrecycletimesFixturesrework,Decreasefixtureusagequantity,Eliminationofexhaustemission,Increasefixturecycletimes,？,？,？,25,2.3.1TestTheMaximumRecycleTimesOfFixtures,2.FixtureRecycleTimes,1.3,G-rayVolumeKeyBottomCoverTestInSep.2008Scrap%,Qualitycontrast,26,2.3.2FixturesRework,BeforeWithoutSticker,AfterWithSticker,Addstickeronthehole,Example:G-rayVolumeKeyBottomBoardFixture,2.FixtureRecycleTimes,Simplereworklikeaddingstickeruponthefixtureswillextendthemaximumrecycletimes.,27,2.3.2.FixturesRework,G-rayVolumeKeyBottomCoverInSep.2008Scrap%,2.FixtureRecycleTimes,Qualitycontrast,28,TheresultsoftheGMMA-RAYfixtureimprovement,Paintedquantity(10k),Recycletimes(2)*Assembledquantity(26pcs),=,193fixtures*Weight(0.0202kg)=3.8986kg,10KproductionofVolumeKeyBottomCoverasanexample,Recycletimes(6)*Assembledquantity(26pcs),=,65fixtures*Weight(0.0202kg)=1.3130kg,Paintedquantity(10k),VS,Reduce2.5856kg/10KIncreaserate66.3%reachouraimedtarget,(Before),(After),2.FixtureRecycleTimes,66.3%,29,StandardizeinWI,2.FixtureRecycleTimes,30,TeamIntroductionOpportunity/BusinessCase/ProjectScopeTargetSettingAndScheduleProjectImplementationAccomplishments/ResultsTeamMembersContactInformation,TableofContent,31,Moreprojectsareapplyingtheabove-mentionedimprovementwithdifferentaccomplishments.,Accomplishments/Results,32,TheResultsOfThePaintsAndFixtureImprovementFromSep.08ToFeb.09,Applyingprojectsresults:Blackberry8000,K530i,K6