喷漆产能提升 DMAIC.ppt

1,ProjectTitlePaintingLineSpaceMagicTeamLeadersNameCC_Szu;KenChang(Reporter)TeamMembersNamesJerryJan,OKLee,TjZhang,LuciusZhu,JeffLiaoLocationGPSCategorySocial&EnvironmentalResponsibility,2,PaintingProcesswouldmakelotsofpollution.Weshoulddoourbesttoreducetherawmaterial.,Paintwasteresiduepool,Paintwasteresidue,Raw,Painted,Material,3,4,PleaseclickthepictureforVCR,5,Waste1.Paint2.Space,Problem,1stWhy,2ndWhy,3rdWhy,Shortenpitch&redesignjig,6,=,Paintcoverarea(Before),Shortenpitchandredesignpaintingfixturecouldeffectivelyreducepaintwaste(50%max).,CircleB1,CircleB2,Howtoincreasepaintusageefficiently？,R2：2*(R/2)2)=2：1,CircleA,CircleB1+CircleB2,Paintcoverarea(After),Comparisonofpaintcoverarea,R,R/2,2DDrawing,7,PlanScheduleofimprovement,P,D,C,A,Plan:Actual:,8,Howfastcanwepayback?,Implement&SavingAnalysis,CosttoimplementUSD32,070includesRotationModification+Spindle+NewJigetcImprovementscenarioUSD20,938isbasedon09Q1-09Q2actualpaintcostofGPS&projected50%paintsaving.,Payback:1.5Day,9,1.Modificationofpaintline,Addingspindlesupportmechanism,SimpleModification:Onlyaddingsupportmechanismtotheoriginallinechain.,Fitsallsizesofpaintareawithgoodcostcontrol.,150mm,10,2.Modificationoftherotation,Twowheels(pitchin175mm)onthetriangularshapefixturewerenotabletoensuretherotationof(new)spindleinmiddle.,Singlewheelensuresrotationofeachspindle,Action:Changethefixturetosinglewheel.,Before,After,11,3.Spindleswayimprovement,Issue:Spindlepulledbymetalchainmechanismeasilygotlooseandliabletospindlesway.Action:1.Usethespindlesstabilizerassupporttoholdspindlesandkeepthespindlesspanat75mm.2.Trimspindletofitinthespindleconnector(10.20.2mmdiameter).3.Lowertheinsertedpintofitinthefixture.,12,Effectivepaintingline,By(A)Shorteningspindlepitchand(B)Redesignjig,thepaintinglinecapacityhasbeenincreasedandpaintsconsumptionreduced.,GPSPaintingLineBProduct:,(B),(A),13,VerificationII:YieldEffect.,TheYieldremainsintact.,14,VerificationI:Paintsaved.,Minimum:16%,Average:37%,Maximum:67%,15,Lengthofcircle(Before),BeforeLength:x2D=2DCapacity:8pcsAfterLength:(xD)x2=2DCapacity:8pcs,Whatisthecapacityafterchange？,Lengthofcircle(After),2D,D,Thelengthofcircledefinesthenumberofpartstobeload.,GoodJigDesign,SameCapacity,16,HowmuchcouldweSave？,Baseontheachievementfromthepilotline&2009Q1-2009Q2actualpaintcost!,Over29millionperyear!,GPSisonlyoneofJGPsites,17,TurnoverboxvolumeJigspindles:15five-partsTotalparts:75parts(5x15),SavingCleanRoomspaceafterimprovement!(Paintinglineincleanroom),Before,After,TurnoverboxvolumeJigspindles:60three-partsTotalparts:180parts(3x60),Theusageofcleanroomspace“save“over100%!,18,Savingconsumptivematerialafterimprovement!,Waterfilter,Paintfilter,19,Smallerpitch,FlexibilityandEfficiencyforProductions,Morepitchoptionforproducts,Increasetheflexibilityforjigdesign,OtherFinding!,Increasecompetitionfor360spraycoating,Smallerpitch,Doubleupthepaintlinecapacity,Morespindlesusedintheprocess,Lessspaceandpaintwaste,Flexibilityandhigherefficiencyfordifferentproduct,Be