Phasefourpresentation.ppt

1、Control Phase 30-Jul-03,Six Sigma Green Belt,Project Description,Project Title: The coil resistance of X15-150 Green Belt: JB Zhu Department: BEL ME Champion / Manager: BH Koh / KS Park End customer: Seagate,Project Description,Problem Statement: The resistance of X15-150 coil is close to upper limi

2、t per winding result, and customer complained three times the resistance out spec. days. Goal/Objective Statement: Currently, the resistance of X15-150LP coil is close to upper limit. But, since we built small quantity samples every lot, so the readings of resistance are consistent and the Cpk is go

3、od. So I will study the mean at the first stage instead of the Cpk, the target is to make the mean of each winding match the spec. mean. For long term target, it is to make the Ppk greater than 1.5 and the resistance match the spec. mean. Other Benefits: 1. Improve the DPPM and prevent scrap. 2. Imp

4、rove the process capability and eliminate customer complain.,Team Member,NameOrganization JB ZhuME Actuator and coil - Leader/Data analysis CL YangME Actuator - Actuator ME JX GuoME Actuator - Coil Post Zhi Ping LiME Coil - Coil winding LY YangME Coil - Measurement,Update Trend Chart,Below is the la

5、test trend chart. This trend chart is based on the coils are all wound by 0.201mm wire. The target of last time is 5.814, per the baseline which is 5.863 this time, the target does not met. Per this trend chart, update the target as 5.82.,Project Timeline,PhaseDeliverablesPlan Due DateActual Complet

6、e Date DTrend Chart April 2, 2003April 04, 2003 + MFishboneMarch 31, 2003March 29, 2003 GR&RApril 01, 2003April 02, 2003 FMEAApril 08, 2003April 07, 2003 + ATrend ChartApril 30, 2003May 5, 2003 Multi-VariMay 7, 2003May 10, 2003 Hypothesis TestsMay 7, 2003May 10, 2003 ANOVAMay 8, 2003May 12, 2003 + I

7、DOE PlanJune 16, 2003June 16, 2003 DOE AnalysisJune 23, 2003June 23, 2003 Revise SettingTBD + CUpdate Trend ChartJuly 28, 2003July 28, 2003 Process Control PlansJuly 29, 2003July 29, 2003 +,Improve phase result,Recall the result from Improve Phase The KPIVs found from Improve phase are: Coil ID & Wi

8、nding Tension Revised setting 0.201mm wire with 2.5N winding tension Reconfirmation run result. Because we have no 0.200 mm wire on hand so we use 0.201mm wire, and the winding tension is 2.5N to reconfirm the setting. 5.8013-0.2270*0.201+0.119*2.5-0.0167*0.201*2.5=6.044 But the actual resistance is

9、 5.689, that suggest the equation is not adequate, there may be other noise factor which will also affect on the coil resistance.,Process Control Plan,Since number of turns is fixed factor, and the wire ID is determined per each lot wire, so the winding tension is the main KPIV will be monitored in

10、future. Current, the technician tests the winding tension every shift. For wire replacement and program adjustment, will also test the winding tension. Current does not monitor the wire ID per each spool, there is just IQC audit each lot. The technician who is responsible for the product will also r

11、esponsible for the monitoring and take action.,Control Chart,Conclusion,Per the control chart at last page, the UCL is 5.901 and the LCL is 5.826. The coil resistance are all measured at coil winding level. Because the coil leads cant be cut at the right length at coil winding level, there must rema

12、in about 20mm for each lead for coil post process convenience. So the actual resistance will be less than the measured value. Will consider to have a compensation next time when make the trend chart.,Issues / Barriers,The experiments are limited by the wire, the special ID wire must be ordered specially, so the cost will increase largely. And the lead time will be too lo