Changqi(John Liu) 6sigma
-
Upload
le-bao-doanh -
Category
Documents
-
view
244 -
download
0
Transcript of Changqi(John Liu) 6sigma
-
8/4/2019 Changqi(John Liu) 6sigma
1/41
8/25/2011 by CJL TOD Confidential 1
Therm-O-Disc Inc. Product Engineering Dept
Performance ImprovementSix W Project EPR 17340
12D Pressure Release Thermal Sensor
Engineering Analysis
Changqi John Liu, Ph.D
Created on 07/20/2005
-
8/4/2019 Changqi(John Liu) 6sigma
2/41
8/25/2011 by CJL TOD Confidential 2
Topics in This Presentation
- Phase (1): Measurement
Project Scope(1)
Problem Statement
Objective
Team Members
Physical Concept for 12D-Temp Control and Pressure Release Valve
Major Output: TFD and Its Standard Deviation Target plan
Cause and Effect Diagram Process Map Analysis
Process Capability Analysis On 3/4/2005 At Project Start
Process Capability Analysis on 04/21/05 and Results Analysis
Improvement (1)-Blank Failure Analysis
Improvement (2)-Second Stress Relief
Improvement (3)-Stability Process
DOE and Results analysis Process Optimization
Confirmation test and results
Conclusions
Project Plan in Future Phase
-
8/4/2019 Changqi(John Liu) 6sigma
3/41
8/25/2011 by CJL TOD Confidential 3
Project Scope
Problem Statement: 12D, Style 46338 Copeland Disc is a newlydeveloped Product. The first temp sorting reject rate is
approximately to 450,000 PPM. Annual volume estimated to reach
4.5 million in 2007. The high rate of first reject discs resulted in
reworking labor increase by 6500 hour per year. The high rate of
final scrap disc resulting in cost increased by $ 283,500 per year.
Objective: By optimizing the process parameters to reduce first
rejection scrapped discs by 10% by July 2005. This will yield about
annually $97,600 cost saving per year. ( In long run, we will try to get
scrap discs less than 150,000 PPM. If the final objective is reached it
will generated about annually $189,000 cost reduction.
-
8/4/2019 Changqi(John Liu) 6sigma
4/41
8/25/2011 by CJL TOD Confidential 4
Team Members
Changqi Liu: Sr. Project Engineer ( Mansfield ) Chen, Jianbang: Sr. Manufacture Engineer (
China )
Wu, Roy: Quality Engineer ( China )
Zhang, Shear: Process Control Engineer ( China )
Support Management Chua, Ck: Lean Manufacturing Manager
Gurski, Mike: Engineering Manager
Evans, Garry: Quality Control Manager
Mansfield Support
Born, Michael; Mueck, Jeff, Disc Dept
-
8/4/2019 Changqi(John Liu) 6sigma
5/41
8/25/2011 by CJL TOD Confidential 5
12D Disc with Different View Point
Snap Action at Open/Close Temp
-
8/4/2019 Changqi(John Liu) 6sigma
6/41
8/25/2011 by CJL TOD Confidential 6
Disc Snap Open to Release the Pressure
-
8/4/2019 Changqi(John Liu) 6sigma
7/41
8/25/2011 by CJL TOD Confidential 7
Primary Metric
Sigma vs. Date
0
1
2
3
4
5
6
7
3/4/2005 4/3/2005 5/4/2005 6/3/2005 7/4/2005 8/4/2005 9/3/2005 10/4/2005 11/3/2005
Date
Sigma
Projected
Target
Actual
It should be here to get ~ 4.2 o F at the
6 project completion
-
8/4/2019 Changqi(John Liu) 6sigma
8/41
8/25/2011 by CJL TOD Confidential 8
Objected Parameter
S No Projected W Average* U S Limit L S Limit Z Level-U Z Level-L PPM-U PPM-L PPM-T FTY
o F o F o F o F %
1 6.50 275.0 268.0 278.0 0.46 1.08 322206 140757 462964 53.70
2 6.00 275.0 268.0 278.0 0.50 1.17 308538 121673 430210 56.98
3 5.50 275.0 268.0 278.0 0.55 1.27 292720 101557 394278 60.57
4 5.00 275.0 268.0 278.0 0.60 1.40 274253 80757 355010 64.50
5 4.50 275.0 268.0 278.0 0.67 1.56 252492 59907 312399 68.76
6 4.00 275.0 268.0 278.0 0.75 1.75 226627 40059 266686 73.33
7 3.50 275.0 268.0 278.0 0.86 2.00 195683 22750 218433 78.16
8 3.00 275.0 268.0 278.0 1.00 2.33 158655 9815 168471 83.15
9 2.50 275.0 268.0 278.0 1.20 2.80 115070 2555 117625 88.24
10 2.00 275.0 268.0 278.0 1.50 3.50 66807 233 67040 93.30
11 1.50 275.0 268.0 278.0 2.00 4.67 22750 2 22752 97.72
12 1.00 275.0 268.0 278.0 3.00 7.00 1350 0 1350 99.87
13 0.50 275.0 268.0 278.0 6.00 14.00 0 0 0 100.00
* Normal Centeris 273o F, It is allowed theactualcentercontrol between272and275o F
W = 4.2 o F ~
1st Sorting Yield to be 70%
The target of the first phase is to obtain first sorting 70 %, final yield to 80%
-
8/4/2019 Changqi(John Liu) 6sigma
9/41
8/25/2011 by CJL TOD Confidential 9
Cause Effect Diagram
-
8/4/2019 Changqi(John Liu) 6sigma
10/41
8/25/2011 by CJL TOD Confidential 10
Process Flow Chart
DPUHeat Treatment
HT123
BlankingB-3093-1
DPUForming
Auto Bumper
DPUStress Relief
SR 103
DPU1st Thermal Cycle
SR 105
Bimetal RM StripRM 99033 MS-10
DPU2nd Thermal Cycle
SR 105
Receiving Insp.MS-10, RMA-14-6
Blanking Insp.QCW C10457
Cleaning
CL-355 & BF-603
DeburringTM-701 & BF-605
12DDisc Style No 46338
Audit / In-Process
QCW B-1425,12D
701
VA VA
VAVA
VA
VAVA
VA
-
8/4/2019 Changqi(John Liu) 6sigma
11/41
8/25/2011 by CJL TOD Confidential 11
Process Flow Chart (2)
DPU
3rd Thermal CycleSR 105
DPU
4th Thermal Cycle
SR 105
Tumbling or SR 103
RFU
Style No 46338
Package
Shipment
4 Pot
Sorting
Yes
No
Cleaning
CL - 355
Dock Audit
BF-609
Inspection Audit
QCW B1425
12D Copeland Disc, Style 46338
VA
NVA
VA VA
VA
-
8/4/2019 Changqi(John Liu) 6sigma
12/41
8/25/2011 by CJL TOD Confidential 12
Process Mapping(1)-BlankingType o KPIVs(Xs) SPECs Gages KPOVS ( ys) Spec Data DPCT/WT RTY
%
CR Thickness MS-10, RM14-6 Digital Checker Thickness Unifor +/-I 0.D11
C Grain Size MS-10, RM14-6 Optical Microscope Grain Size No. > 8
C HES Hardness MS-10, RM14-6 Micro-Hardness Tester Hardness Value 210~260
C LES Hardness MS-10, RM14-6 Micro-Hardness Tester Hardness Value 260~315
C Cross Flatness MS-10, RM14-6 Special Tester Cross Curvature < 0.008"
N Bonding Strength MS-10, RM14-6 Special Method, Visual De-layminated 0.005 1 Days CT 99.5
C RM MS-10, RM14-6 Dimple Height B-3093
N Cut MS-10, RM14-6 Visual Control Profile Hx B-3093
N Layer MS-10, RM14-6 Visual Control Profile Hy B-3093
CR Punches Dr. B-3093 Profilimeter Diameter D B-3093
CR Setup BF-701 System Control Number Per Bag 320 o F 0.05 60 Min 95
C Pieces/Bag BF 705 BF 701
Vib. Frequency BF 706 Set
Time BF 707 Timer Round Corner Radii 5E-04 45 Min 99.95
Total 0.054 3 Days 94.6
DPU
Stamping
Raw Material
RM 99033
Cleaning
CL-355, BF603
Heat Treatment
Deburing
Blank AuditCW-10457
VA
VA
VA
NVA
Inspection
MS-10, RM-14-6
Store Room
BF 605
NVA
VA
-
8/4/2019 Changqi(John Liu) 6sigma
13/41
8/25/2011 by CJL TOD Confidential 13
Process Mapping(2)-Calibration
-
8/4/2019 Changqi(John Liu) 6sigma
14/41
8/25/2011 by CJL TOD Confidential 14
PFMEA(1)
Diff
n
FD/BFD f
each disc res
l
in
s
andard deviati
n wide
Coolin
Rate
Chan
ed
Conveyernot s
ooth to
deliverDiscs are Wrapped
Could not form the discFormin
ability too low
check every 20th lotToo Low Temp, EQ out ofControlchan
e.
Contact
maintenan
ce
2
84Metrology Instron1
Too high Temp, EQ. Out of
Control
Forming ability
ChangedForming conditions
Heat
Treatment
4
Disc equipment tooling wear.
check Burr
Punch tool is dull resulting in too
much burrsharp edge
Tooling
needs
grinding.
1
05Deburr operator1Vibration time too short2
Disc operation effected
by
Edge burr exceeds
.001"Deburring
3
present
Contact
maintenan
ce
3
24
Q.A. Visual
Inspection2
Cleaning process has poor
filtration.4
Disc oil and
contaminationOil or contaminationCleaning
2
dia. and profile.operate correctlyout ofspecification
81
Press operator
checks1Tooling d imensions incorrect8Disc willnotBlank D imensionBlanking1
Recomme
nded
Action(s)
R
P
N
D
e
t
Current Process
ControlsO
c
c
Potential Cause(s)/ Mechanism(s)
ofFailureS
e
v
Potential Effect(s) of
Failure
PotentialFailure
Mode(s)
Process
Function
Requirements
Item
#
JIHGFEDCBA
-
8/4/2019 Changqi(John Liu) 6sigma
15/41
8/25/2011 by CJL TOD Confidential 15
Improvement (1)
Effect of RM and Blanking
RM Thickness Uniformity Parameter Uniformity Blank Number of Blank Disc Per Bag
HY Lesson Failure Analysis
Large Number Risk
Low Yield Disc Unstable
It is not the HT and Cleaning Process that depend the Numberof Blank Per Bag.
It is Major the RM Parameter variation to Determine the
Number Per Bag Blank Number Should be Optimized, A Plan was sent to China
plant to do tests Yield vs. Number of Blank per Bag
-
8/4/2019 Changqi(John Liu) 6sigma
16/41
8/25/2011 by CJL TOD Confidential 16
Improvement(2)
Second Time Stress Relief
Second Time Stress Relief was done in China
Plant which was originally used to correct the
bad HY blank. After the blank was corrected, it is
still being used in production.
To increase the stability of disc.
It can be get more upper and lower limit
from 268/276 to 268/278 in process. It is proved to increase the life cycles also.
-
8/4/2019 Changqi(John Liu) 6sigma
17/41
8/25/2011 by CJL TOD Confidential 17
Process Analysis Step by Step on
4/21/05
PRA AsFed AS-SR As-1stC As-2ndC As-3rdC As-4thC 1stST
o F
Average 297.73 276.49 272.45 273.48 275.49 275.37 276.09
Stdev 7.69 7.24 5.87 7.14 6.14 5.10 4.98
Max 301.10 290.20 285.30 287.40 288.70 286.90 287.10
Min 294.50 264.40 258.70 257.80 265.20 267.30 267.80
Range 6.60 25.80 26.60 29.60 23.50 19.60 22.30
-
8/4/2019 Changqi(John Liu) 6sigma
18/41
8/25/2011 by CJL TOD Confidential 18
Process Capability at 4/25/05
284280276272268264
LSL U SL
Process Data
Sample N 120
StDev(With in) 5.25000
StDev(O veral l) 5.12431
LSL 267.00000
Target *
U SL 283.00000
Sample Mean 273.40000
P otential (Within) C apability
C PU 0.61
C pk 0.41
Lower C L 0.33
Upper C L 0.49
C C pk 0.51
C p
O verall C apability
P p 0.52
Lower C L 0.45Upper C L 0.59
P P L 0.42
P P U
0.51
0.62
P pk 0.42
Lower C L 0.34
Upper C L 0.50
C pm *
Lower C L
Lower C L
*
0.44
Upper C L 0.57
C PL 0.41
O bserve d P erformance
PP M < LSL 125000.00
PPM > USL 25000.00
PPM Tota l 150000.00
Exp. Within Performance
PPM < LSL 111413.06
PPM > USL 33731.92
PPM Tota l 145144.98
Exp. O v erall Performance
PPM < LSL 105842.15
PPM > USL 30505.13
PPM Total 136347.28
W ithin
O v erall
Process Capability For 12 D 463 38 Disc Thermal Sensor(using 95.0% confidence)
-
8/4/2019 Changqi(John Liu) 6sigma
19/41
8/25/2011 by CJL TOD Confidential 19
Plan in Improvement Phase
Blank Number Optimization: WAs formed vs. numberof blanks per bag (1500, 1750, 2000, 2250pieces/bag)
HT Temp Optimization
Use Appropriated HT System to get the right Open andDifferential ( 275/100 o F) Special for 12D 46338
Punch Effect and Optimization
SR and Stability Optimization
Combination Effect DOE Test To get best two levels for above four factors to do the
design of experimental
-
8/4/2019 Changqi(John Liu) 6sigma
20/41
8/25/2011 by CJL TOD Confidential 20
Improvement (3)
Design Experiment Analysis
Affecting Factors HT Temp, Time, Temp Creasing, Cooling Rate, Number per
container
Forming Conditions Penetration 1 and Penetration II
Punch effect: Spherical Radium of 1st Punch
SR Temp, Time, Temp Increasing Rate, Cooling Rate Number Per
Basket
Thermal Cycles
Cycle time, Temp, Number Per Basket
If each factor takes 2 levels, it will be 215 tests. It is too many
tests to be performable. We need a Blocking Method.
-
8/4/2019 Changqi(John Liu) 6sigma
21/41
8/25/2011 by CJL TOD Confidential 21
DOE Analysis
In this phase, the DOE will focus on SR andThermal Cycles
Factors selected
Number of Disc Per Container SR - Temp
Thermal Cycle Temp and Cycle Times
Altogether four factors, Each factor has two
levels, The Complete tests are 24. It still toomany. we will take 8 tests
-
8/4/2019 Changqi(John Liu) 6sigma
22/41
8/25/2011 by CJL TOD Confidential 22
Table I Factors and Levels Being Selected
Factor Level Low (Code: -1) Level High (Code: +1) Factor Code
Stress Relief Temp 550 o F / 20 Min. 700 o F / 20 Min. A
Disc # per Basket 250 Per Container 500 Per Container B
Cycle Number 2 Cycles 4 Cycles C
Cycle Temp 310 o F/10 Min 550 o F /10 Min D
StdOrder RunOrder SR T Disc No Cycle No TC Tem
4 1 1 1 -1 -1
1 2 -1 -1 -1 -1
5 3 -1 -1 1 1
6 4 1 -1 1 -13 5 -1 1 -1 1
7 6 -1 1 1 -1
2 7 1 -1 -1 1
8 8 1 1 1 1
-
8/4/2019 Changqi(John Liu) 6sigma
23/41
8/25/2011 by CJL TOD Confidential 23
Planned Tests
Run No SR Temp Disc No PerB Cycle No. C- Temp
1 550F/20 Min 250 2 310F/10 Min
2 550F/20 Min 500 4 310F/10 Min
3 550F/20 Min 250 4 550F/10 Min
4 700F/20 Min 500 4 550F/10 Min
5 700F/20 Min 250 2 550F/10 Min
6 550F/20 Min 500 2 550F/10 Min
7 700F/20 Min 250 4 310F/10 Min
8 700F/20 Min 500 2 310F/10 Min
-
8/4/2019 Changqi(John Liu) 6sigma
24/41
8/25/2011 by CJL TOD Confidential 24
Test Results
Run I Run II Run III Run IV
TFD BFD TFD BFD TFD BFD TFD BFD
Average 297.1 185.2 293.0 184.0 294.1 181.4 294.0 187.6
Stdev 6.62 5.20 6.59 4.95 6.87 5.13 7.24 4.41
Max 306.7 195.3 309.3 195.3 309.7 195.1 313.3 195.6
Min 282.4 175.2 280.5 169.3 283.7 174.3 284.6 180.6
Range 24.3 20.1 28.8 26.0 26.0 20.8 28.7 15.0
RUN V RUN VI Run VII Run VIII
TFD BFD TFD BFD TFD BFD TFD BFD
Average 275.6 174.9 276.9 176.5 276.8 175.5 274.9 175.7
Stdev 4.88 4.15 4.85 5.40 6.85 4.35 6.43 6.04
Max 285.9 188.0 286.5 195.8 292.8 184.2 286.7 195.3
Min 265.2 168.2 268.3 167.7 264.4 168.8 263.1 164.5
Range 20.7 19.8 18.2 28.1 28.4 15.4 23.6 30.8
30 pieces of samples were taken to do stat check
-
8/4/2019 Changqi(John Liu) 6sigma
25/41
8/25/2011 by CJL TOD Confidential 25
TFD Stdev
Run No SR Disc No TC No TC Temp Stdev
o F Pieces Cycles o F o F
1 550 250 2 310 5.28
2 550 250 4 550 5.483 550 500 2 550 5.12
4 550 500 4 310 5.99
5 700 250 2 550 3.58
6 700 250 4 310 4.09
7 700 500 2 310 4.81
8 700 500 4 550 5.58
-
8/4/2019 Changqi(John Liu) 6sigma
26/41
8/25/2011 by CJL TOD Confidential 26
Main Effect on The Results
MeanofResults
1-1
5.50
5.25
5.00
4.75
4.50
1-1
1-1
5.50
5.25
5.00
4.75
4.50
1-1
SR T Disc No
Cycle No T C T em
Main Effects Plot (data means) for Results
High Temp will resulting in a lower Standard Deviation
Less number of discs in a container will result in a lower Stdev
Less thermal cycles will result in a lower Stdev
Thermal Cycles Temp will not be of large effect
-
8/4/2019 Changqi(John Liu) 6sigma
27/41
8/25/2011 by CJL TOD Confidential 27
Interaction
SR T
1-1 1-1 1-1
6
5
4
Disc No
6
5
4
Cycle No
6
5
4
TC Tem
SR T
-1
1
Di
-1
1
Cycl
-1
1
InteractionPlot (datameans) for Results
When SR temp at high level, 250 disc discs in a container willresult in a lower standard deviation
When 2 cyclic number was taken with the high ST temp, it will
help to reduce the stdev
-
8/4/2019 Changqi(John Liu) 6sigma
28/41
8/25/2011 by CJL TOD Confidential 28
Analysis of Variance for Results (coded units)
Source DF Seq SS Adj SS Adj MS F P
Main Effects 4 3.7040 3.7040 0.9260 * *
2-Way Interactions 3 0.8157 0.8157 0.2719 * *
Residual Error 0 * * *
Total 7 4.5197
-
8/4/2019 Changqi(John Liu) 6sigma
29/41
8/25/2011 by CJL TOD Confidential 29
Estimated Effects and Coefficients for Results
(coded units)
Term Effect Coef
Constant 4.9913
SR T -0.9525 -0.4763
Disc No 0.7675 0.3837
Cycle No 0.5875 0.2938
TC Tem -0.1025 -0.0513
SR T*Disc No 0.5925 0.2963
-
8/4/2019 Changqi(John Liu) 6sigma
30/41
8/25/2011 by CJL TOD Confidential 30
Effect of Factors
Term
Effect
AC
D
AD
C
AB
B
A
3.53.02.52.01.51.00.50.0
3.306Factor
TC Tem
Name
A S R T
B Disc N o
C C y cle N o
D
Pare to Chart of the Effects(response is Results, Alpha = .05)
Lenth's PSE = 0.87825
Thermal Cycle Temp (D) effect is small
AC and AD effect are small either
-
8/4/2019 Changqi(John Liu) 6sigma
31/41
8/25/2011 by CJL TOD Confidential 31
Factorial Fit: Results versus SR T, Disc No,
Cycle No
After taking away the thermal temp factor:Estimated Effects and Coefficients for Results (coded units)
Term Effect Coef SE Coef T P
Constant 4.9913 0.07490 66.64 0.000SR T -0.9525 -0.4763 0.07490 -6.36 0.008
Disc No 0.7675 0.3837 0.07490 5.12 0.014
Cycle No 0.5875 0.2938 0.07490 3.92 0.029
SR T*Disc No 0.5925 0.2962 0.07490 3.96 0.029
S = 0.211847 R-Sq = 97.02% R-Sq(adj) = 93.05%
-
8/4/2019 Changqi(John Liu) 6sigma
32/41
8/25/2011 by CJL TOD Confidential 32
Main Effect Factors
Term
Standardized Effect
C
AB
B
A
76543210
3.182 Factor NameA SR T
B Disc No
C C ycle No
Pareto Chart of the Standardized Effects(response is Results, Alpha = .05)
The main factors of the A SR Temp, B - Disc Number per container,
C Number of thermal cycles
-
8/4/2019 Changqi(John Liu) 6sigma
33/41
8/25/2011 by CJL TOD Confidential 33
Residuals
Residual
Percent
0.40.20.0-0.2-0.4
99
90
50
10
1
Fitted Value
Residual
5.55.04.54.03.5
0.2
0.1
0.0
-0.1
-0.2
Residual
F
requency
0.20.10.0-0.1-0.2
1.00
0.75
0.50
0.25
0.00
Observation Order
Residual
87654321
0.2
0.1
0.0
-0.1
-0.2
Normal Probability Plot of the Residuals Residuals Versus the Fitted Values
Hist og ram o f t he R esid uals R esid uals Versus t he Ord er o f t he Dat a
Residual Plots for Results
-
8/4/2019 Changqi(John Liu) 6sigma
34/41
8/25/2011 by CJL TOD Confidential 34
Analysis of Variance for Results (coded units)
Source DF Seq SS Adj SS Adj MS F P
Main Effects 3 3.6829 3.6829 1.22765 27.35 0.011
2-Way Interactions 1 0.7021 0.7021 0.70211 15.64 0.029
Residual Error 3 0.1346 0.1346 0.04488
Total 7 4.5197
-
8/4/2019 Changqi(John Liu) 6sigma
35/41
8/25/2011 by CJL TOD Confidential 35
Effect Equation Obtained
= 4.9913 0.476TSR+ 0.384NDisc + 0.2938NCycles +0.296TSRNDisc
Optimized Process Conditions
SR Temp (TSR) 700o F/ 20Min
Number of Disc (NDisc) 250 Pieces Per Container Thermal Cycles (NCycles) 2 Cycles
Thermal Cycle Temp 550 o F /20 Min
-
8/4/2019 Changqi(John Liu) 6sigma
36/41
8/25/2011 by CJL TOD Confidential 36
Confirmation Test & More Improvement
Group I SR 700 F/20 Min, 250 pieces/PC ;2 Cycles/Air Cooling, 550 F/10 Min
Group II SR 700 F/20 Min, 250 pieces/PC 2 SR ;
2 Cycles/Air Cooling, 550 F/10 Min
To See if 2 times of SR will improve the Sigma
Group III SR 700 F/20Min, 250 Pieces/PC;
4 Cycles, 310F/10 Min
Sorting Oil heating and Cooling
Group IV SR 700 F/20Min, 250 Pieces/PC-2 SR ;4 Cycles , 310F/10 Min
Sorting Oil Heating and Cooling,
-
8/4/2019 Changqi(John Liu) 6sigma
37/41
8/25/2011 by CJL TOD Confidential 37
Confirmation Test Results
Test 1 Test 2 Test 3 Test 4
TFD BFD TFD BFD TFD BFD TFD BFD
Averag
e 274.30 174.17 271.45 174.07 270.94 173.08 271.27 174.85
Stdev 4.03 3.81 3.59 2.89 2.43 2.78 3.92 4.03
Max 280.30 178.50 282.60 180.10 277.60 177.30 282.70 189.90
Min 263.30 164.40 264.60 169.60 265.90 166.10 263.70 166.80
Range 17.00 14.10 18.00 10.50 11.70 11.20 19.00 23.10
-
8/4/2019 Changqi(John Liu) 6sigma
38/41
8/25/2011 by CJL TOD Confidential 38
Primary Metric
Sigma vs. Date
0
1
2
3
4
5
6
7
3/4/2005 4/3/2005 5/4/2005 6/3/2005 7/4/2005 8/4/2005 9/3/2005 10/4/2005 11/3/2005
Date
Sigma
Projected
Target
Actual
We are here W ~ 5 o F
Objective ~ 4.2 o F on 7/20/05
We have now reached: < 4 o F
-
8/4/2019 Changqi(John Liu) 6sigma
39/41
8/25/2011 by CJL TOD Confidential 39
Projected Parameters
S No Projected W Average* U S Limit L S Limit Z Level-U Z Level-L PPM-U PPM-L PPM-T Yield
o F o F o F o F %
1 6.50 275.0 268.0 278.0 0.46 1.08 322206 140757 462964 53.70
2 6.00 275.0 268.0 278.0 0.50 1.17 308538 121673 430210 56.98
3 5.50 275.0 268.0 278.0 0.55 1.27 292720 101557 394278 60.57
4 5.00 275.0 268.0 278.0 0.60 1.40 274253 80757 355010 64.50
5 4.50 275.0 268.0 278.0 0.67 1.56 252492 59907 312399 68.76
6 4.00 275.0 268.0 278.0 0.75 1.75 226627 40059 266686 73.33
7 3.50 275.0 268.0 278.0 0.86 2.00 195683 22750 218433 78.16
8 3.00 275.0 268.0 278.0 1.00 2.33 158655 9815 168471 83.15
9 2.50 275.0 268.0 278.0 1.20 2.80 115070 2555 117625 88.24
10 2.00 275.0 268.0 278.0 1.50 3.50 66807 233 67040 93.30
11 1.50 275.0 268.0 278.0 2.00 4.67 22750 2 22752 97.72
12 1.00 275.0 268.0 278.0 3.00 7.00 1350 0 1350 99.87
13 0.50 275.0 268.0 278.0 6.00 14.00 0 0 0 100.00
* Normal Centeris 273F, It is allowed theactualcentercontrol between272and275o F
When < 4 o F,
1st sorting Yield will be ~ 75%
-
8/4/2019 Changqi(John Liu) 6sigma
40/41
8/25/2011 by CJL TOD Confidential 40
Conclusions
By Optimizing the Stability Conditions as below: SR 700 o F / 20 Min. 250 pieces/Per Condition
2 Thermal Cycle with temp as 550 o F /10 Min.
It is able to improve the performance:
The first Sorting yield increased from 50 % to 75% The final yield will be more than 80%.
This corresponds to an approx labor saving of 4000hrs.
The 10% yield improvement corresponds to a costreduction of approx. $80,000 per year. ( 4 milliondiscs per year in production )
-
8/4/2019 Changqi(John Liu) 6sigma
41/41
8/25/2011 by CJL TOD Confidential 41
Future Works
Effect of the blank number on the Forming Effect of Punch Spherical Radius on the
Forming
Second Phase ImprovementTarget: 10-15% improvement
TFD Stdev Target should be < 1.75 o F
Third Phase Improvement Long Run
Maximum is about 19.9 % of improvement
TFD Stdev Target should be < 1 o F