CIP项目标准模板

1、Project Name: Prepared by : Checked by : Date: Business Case (why selected) Define Measure Analyze Improve Control Describe the current financial impact of the problem, i.e. how much money is currently wasted because of the problem. This waste of money may be due to e.g. scrap, rework, repair, slow

2、cycle time, bottlenecks, poor utilization of capacity, inventory costs, warranty costs, lost volume, lost opportunities, etc. Practical Problem Definition Problem Statement: Project Objectives: Define Measure Analyze Improve Control Project Team Sponsor the project; Resource support; Manage and Appr

3、aise MBB and BB. Lead and manage the project; Training the GB and team members; Coordinate between members and departments; Follow up the project phase; Manage and Evaluate GB. Collect the data for analysis; Process Capability Study; MSA; Execute the improvement plan with project members; Keep good

4、communication between suppliers and project team; As a consultant, direct the project; Training GB and team members. Collect relative data; Negotiation with suppliers on quality requirement. Collect relative data; Incoming quality inspection; Collect the data for analysis; FMEA; Process Capability S

5、tudy; MSA; Execute the improvement plan with project members; Optimize the process; FMEA; Process Capability Study; MSA; Execute the improvement plan with project members; Support the project and keep production line running when project needed; Assign the operator and line for project experiment. A

6、ssign technician to adjust the machine and parameter setting; Execute the improvement plan with project members; Technical support for the improvement project; Execute the improvement plan with project members; Responsibilities Define Measure Analyze Improve Control Primary Metric Define Measure Ana

7、lyze Improve Control Business Impact (cost savings estimated) Define Measure Analyze Improve Control Project Gantt Chart Define Measure Analyze Improve Control Phases Timeline Main Activities July AugSeptOct Nov Dec Define Business case Project scope & objective Team set up Measure MSA for Y and Xs

8、Process Capability Assessment Cause & Effect Analysis Screen potential causes Fast improvement measures Analyze Status analysis for Xs Statistical analysis and verification for Xs Improve Actions piloted Result verification Control Standardization Control plan & SPC Cost savings verification Respons

9、e Variable (Y) Response Variable and Specification: Measurement System Description: Define Measure Analyze Improve Control Project Scope Define Measure Analyze Improve Control Measurement System Analysis Objective: Verify the Measurement System for Standby Power Testing by Variable Gauge R&R method.

10、 Standby Power Tester Model: Digital Power Meter_1 Sample Size: 10pcs Method: 2 Test Operators, test 3 time for each sample % R&R=sMS/sTotal *100=%SV= 4.33% 14% (Ideal) % P/T=5.15*sMS/Tolerance *100= %SV/Toler=2.45% 10(Ideal) So, the Measurement System for Standby Power Test should be acceptable acc

11、ording to the above GR&R result. Conclusions: Study Var %Study Var %Tolerance %Process Source StdDev (SD) (6 * SD) (%SV) (SV/Toler) (SV/Proc) Total Gage R&R 0.0030639 0.018384 4.33 2.45 5.11 Repeatability 0.0030639 0.018384 4.33 2.45 5.11 Reproducibility 0.0000000 0.000000 0.00 0.00 0.00 Operator 0.

12、0000000 0.000000 0.00 0.00 0.00 Part-To-Part 0.0707398 0.424439 99.91 56.59 117.90 Total Variation 0.0708061 0.424837 100.00 56.64 118.01 Number of Distinct Categories = 32 Define Measure Analyze Improve Control Analysis of Capability Define Measure Analyze Improve Control Process Map Wrong wire Ins

13、ulation damage Wrong numbers of turns Incorrect wire tension Pin bended P o o r a s s e m b l y (not to bottom) C Pin C Fixture U Operator C Bobbin dimension C Magnetic wire_Dia C Winding Parameter (travel/tension/spee d) U Operator Wrong wire Insulation damage Wrong numbers of turns Incorrect wire

14、tension C Pin C Soler wire C Temperature C Time U Operator Cold solder Wrong tin wire No solder Excesssive solder C Fixture U Operator Wire broken Mal-assembly C Fixture C EI core dimension C EI core burrs U Operator U Machine Adjust EI core bending Demage bobbin EI core side not identical C EI core

15、 U Operator U Machine Adjust EI core bending EI core loose Visual defect C T e s t e r m a l - function U Operator Cycle time Yield Pass the transformer which not been tested C Dipping time C Dipping depth U Machine vibration U Varnish viscosity U Operator U Fixture Cycle time EI core loose Visual d

16、efect C Drying Time C Temperature U Operator U Oven Structure Cycle time Transformer demage C Input Voltag e / Current C Tester C Transformer U Operator Voltage _No load High Standby power Hi-pot/Insulation Visual Defect Prepare Raw Material, MPI, Equipment, Operator etc Primary Winding Soldering wi

17、re Press pin Bobbin and bobbin cover Assembly Stacking EI core Press EI core Electrical Function Testing Varnish Drying Functional Testing Next Process Secondary Winding ProcessInputOutputProcessInputOutput VA VA VA VA VA VA VA VA NVA VA VA NVA Define Measure Analyze Improve Control C&E Matrix To li

18、nk the C&E Matrix to the Process Map and Relates the KPIVs to the KPOVs with a simplified QFD matrix. Define Measure Analyze Improve Control RatingRating of Importance to customer of Importance to customer 1044 NoNo12345 ProcessProcess Output Output Total NoProcessProcessProcessProcess Input Input(

19、(X)X) XY 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 0 100 0 110 0 120 0 130 0 140 0 150 0 160 0 170 0 180 0 19 0 0 20 0 0 21 0 0 22 0 0 23 0 0 24 0 0 C&E MatrixC&E Matrix PFMEA FMEA is structured approach to Identify ways the product or process can fail and eliminate or reduce the risk of failure. D

20、efine Measure Analyze Improve Control Summary of M Phase Define Measure Analyze Improve Control Identification of Likely Xs Xs related to Raw Material Xs related to Process& Equipment Define Measure Analyze Improve Control Define Measure Analyze Improve Control Summary of Most Likely Xs Xs related t

21、o Raw Material EI core Thickness(0.5+/-0.03) Different EI core Suppliers Dimension Measurement System Control in IQA Bobbin Cover Height (18.15+0/-0.15) Xs related to Process Bobbin/cover deformation after winding process, which may cause high standby power and will be studied in DOE phase. Winding

22、Process Parameter setting Winding Speed Winding Tension Winding Travel Define Measure Analyze Improve Control Summary of A Phase Biggest Problems and Barriers: Project Status: J Define Measure Analyze Improve Control Central Composite Design Factors: 3 Replicates: 1 Base runs: 20 Total runs: 20 Base

23、 blocks: 1 Total blocks: 1 Two-level factorial: Full factorial Cube points: 8 Center points in cube: 6 Axial points: 6 Center points in axial: 0 Alpha: 1.68179 Purpose: This DOE aims to verify the linear/quadratic effects and interactions between parameter settings to Standby Power by Central Composite Design. Design of Experiments Speed 3 levelLow: 6000