1、FDD DepartmentNOV-23-20001q6 Sigma Project 登錄書q6 Sigma Project 步驟書qMeasure - PhaseqAnalyze - PhaseqImprove - PhaseqControl - Phaseq6 Sigma Project 結(jié)束報(bào)告書NOV-23-20002Head Carriage(Nut Miss)Spindle Motor AssyCarriage-UP AssyHGA Side0PCB-Main Assy(FDD)Bezel AssyOthers8814680422476911743710131 5238121373

2、3.730.818.3 6.7 3.9 2.0 4.6 33.7 64.5 82.8 89.5 93.3 95.4100.00100000200000020406080100DefectCountPercentCum %PercentCountPareto Chart for Material DesD廢棄金額最大NOV-23-20003部門長推進(jìn)事務(wù)局財(cái)會(huì)TEAM 長ChampionBond涂抹工程，Nut 熔著工程，Carrige Upper 組立工程。Leader楊 進(jìn)部門長鄧常松 PROJECTDMAIC周建良 推進(jìn)日程9/39/209/219/30 10/310/30 11/112/

3、1 12/112/30賀志才NUT 原材料尺寸不良；Nut原材料改善；問題點(diǎn)Carriage Lower Nut組立Hole設(shè)計(jì)問題；Carriage Lower Nut Hole 設(shè)計(jì)變更；(現(xiàn)水準(zhǔn))富鋼NUT組立工程壓入不良；富鋼相關(guān)作業(yè)者作業(yè)方法，組立設(shè)備改善Main Line Carriage Upper組立不良。Main Line作業(yè)者教育。效果金額 單品在工 材料費(fèi)基準(zhǔn)材料費(fèi)： (5710-1000)*70000*(6.5+1)*27*12/10000000=801,171RMB向上率成果指標(biāo)活動(dòng)前劉曉星PROJECT 活動(dòng)期間 2000 . 10 .3 . 2001 . 1 .

4、31 .活動(dòng)方向樸夏律金英浩工程不良率活動(dòng)后PROJECT名關(guān)聯(lián) Process指導(dǎo) BB活動(dòng)MemberCarriage Lower NUT 脫落不良改善樸 夏 律Sigma水準(zhǔn)5710PPM82.50%4.031000PPM4.59現(xiàn)水準(zhǔn)PROJECT 效果效果NOV-23-200046 SIGMA Project 步驟書步驟書PROJECT 選定事由現(xiàn)象確認(rèn)(問題中心)工程不良率高，關(guān)聯(lián)原材料浪費(fèi)嚴(yán)重，* WHAT(對(duì)象)影響工程品質(zhì)及生產(chǎn)性，且不良原因集中Nut & Carriage Lower* WHERE(關(guān)聯(lián)工程)Nut 熔著工程、S1組立工程* HOW(關(guān)聯(lián)指標(biāo))Sec

5、ew 組立不可現(xiàn)象確認(rèn)2(4M側(cè)面)效果S* 給部門帶來的影響* MANNut 熔著工程人員，降低產(chǎn)品返修率，提高工程品質(zhì)及生產(chǎn)性S1組立工程人員O* MACHINENut 熔著機(jī)S1組立DriveL* 給顧客帶來的影響*MATERIALNut & Carriage Lower提高產(chǎn)品信賴性，降低User不良率，V達(dá)到客戶滿足的要求。*METHODNut 熔著工程作業(yè)方法教育S1組立工程作業(yè)方法教育E最高目標(biāo) GAP 分析解決方案(對(duì)策)Sensor原材料彈性增強(qiáng)；為測(cè)定分析的適用方法關(guān)聯(lián)Jig重新調(diào)整；相關(guān)作業(yè)者作業(yè)方法教育；Nut熔著JIG Gauge R&R 評(píng)價(jià)Line

6、 別工程不良統(tǒng)計(jì)比較。Driver Torque 管理ImplementChartNOV-23-20005NUT press & drillN-作業(yè)者N-設(shè)備偏差C-Drive TorqueC-S1組立JigN-作業(yè)者涂抹量N-Bond涂抹均勻性C-Bond澆口大小C-Bond干燥時(shí)間C-Bond 性能N-作業(yè)者Nut安放C-壓入Jig定位C-壓入Jig Air pressC-壓入Jig沖頭行程C-工作臺(tái)異物 S-壓入Jig的潤滑N-作業(yè)者S-設(shè)備預(yù)熱S-模具溫度C-模具尺寸C-部品結(jié)構(gòu)C-成型毛刺C-材料性質(zhì)Nut & Carriage Lower AssemblyBond

7、涂抹工程涂抹工程S1 AssemblyS1 & Carriage Lower組立Nut 外圍Bond 涂抹Nut & Carriage Lower 組立Carriage Lower成型成型C/L注塑成型Nut Press Nut DrillN-作業(yè)者N-設(shè)備震動(dòng)C-模具精度C-模具保養(yǎng)C-Drill Macheine精度C-定位精度C-材料性質(zhì)S-設(shè)備潤滑MNOV-23-20006作業(yè)不標(biāo)準(zhǔn)外觀檢查不良NUT 模具不良Bond涂抹不均或量少Nut 壓入Jig 不良Nut 壓入Jig Air 不良Nut 外徑尺寸不良Nut同心度不良Nut drill不良C/L 內(nèi)徑尺寸不良Bon

8、d 粘度不良Drive Torque 過大目視檢查Nut 測(cè)試不良模具別偏差Bond 保管處溫度高PersonnelMachinesMaterialsMethodsMeasurementsEnvironmentNut 脫落不良分析Nut 脫落不良脫落不良MMeasurementsMaterialsMenMethodsMachinesEnvironmentNOV-23-20007M12345678910OutputVariables (Ys)Nut&C/L配合配合狀況狀況Bond 粘著力粘著力Nut壓入狀況壓入狀況Nut 脫落程度脫落程度OutputRanking98710Input V

9、ariables (Xs)Association TableRank% Rank1Nut 外徑尺寸外徑尺寸9191025212.47%2Nut Screw 同心度同心度111101246.14%3Nut Screw破損破損11191145.64%4C/L內(nèi)徑尺寸內(nèi)徑尺寸8181023611.68%5C/Lhole 外型外型619820510.14%6Bond 涂布量涂布量210191959.65%7Bond 粘性粘性19191788.81%8Bond涂布均勻度涂布均勻度17171427.03%9壓入壓入Jig Air Press11991708.41%10壓入壓入Jig 定位定位2187152

10、7.52%11Drive Qurque11181045.15%12組立作業(yè)方法組立作業(yè)方法312101497.37%13141516View ResultsDeleteInstructionsDEMONOV-23-20008 Characteristic Selection MatrixResults0%10%20%30%40%50%60%70%80%90%100%Nut 外徑尺寸Nut Screw 同心度Nut Screw破損C/L內(nèi)徑尺寸C/Lhole 外型Bond 涂布量Bond 粘性Bond涂布均勻度壓入Jig Air Press壓入Jig 定位Drive Qurque組立作業(yè)方法In

11、put CharacteristicCharacteristic Importance (%)M改善必要!NOV-23-20009MPotential Failure Modes and Effects Analysis Process Name: Track00 AlignmentProcess Responsibility:工程技術(shù)隊(duì)Affected Product(s): 3.5 Double High Density FDDPFMEA Key Date: 1999年12月20#ProcessFunction (Step)Potential FailureModes (processde

12、fects)Potential FailureEffects (Ys)SEVClasPotentialCauses ofFailure (Xs)OCCCurrentProcessControlsDETRPNRecommendActions1Nut Press&Drill模具凹模尺寸不良Nut外徑尺寸不良9模具不良6模具制造管理5270Nut Drill 不良Nut Screw 不良10Drill Machine 不良2Drill 設(shè)備控制480Nut Drill定位不良Nut 同心度不良10定位Jig 不良3Drill 定位Jig精度390材料不良Nut 尺寸變形9材料不良3QC抽檢5

13、135模具磨損Nut 尺寸不良10模具不良5定期保養(yǎng)42002Carriage Lower模具凸模尺寸不良C/L尺寸不良10模具不良5模具制造管理4200注塑條件不良C/L尺寸變化8設(shè)備管理不良3標(biāo)準(zhǔn)操作者管理372模具型芯尺寸不良Nut 定位不良10模具不良5模具制造管理5250Resin 不良C/L尺寸變化7原材料不良3QC抽檢242C/L 內(nèi)異物C/L 壓入變形85S管理不足4生產(chǎn)管理396NOV-23-200010M#ProcessFunction (Step)Potential FailureModes (processdefects)Potential FailureEffects

14、 (Ys)SEVClaPotentialCauses ofFailure (Xs)OCCCurrentProcessControlsDETRPNRecommendActions3Nut&C/L AssemblyNut 安放不好Nut 壓入不良8作業(yè)者疏忽4外觀檢查100%目測(cè)396壓入Jig Air Press未管理壓力不足8設(shè)備管理不良6無管理7336壓入Jig 定位不良C/L破損8設(shè)備不良5設(shè)備定期管理4160壓入Jig沖頭BendNut 壓入變形9設(shè)備不良3設(shè)備定期管理4108壓入Jig沖頭行程不足Nut未壓緊9設(shè)備不良4設(shè)備定期管理62164Bond涂布工程涂布不均勻Nut 粘

15、著力不強(qiáng)7作業(yè)方法無標(biāo)準(zhǔn)化，作業(yè)者品質(zhì)意識(shí)差6外觀檢查100%目測(cè)8336涂布量不足Nut 粘著力不強(qiáng)7作業(yè)方法無標(biāo)準(zhǔn)化，作業(yè)者品質(zhì)意識(shí)差5外觀檢查100%目測(cè)7245Bond涂布器澆口不良Bond 涂量不足7作業(yè)工具無標(biāo)準(zhǔn)化5無管理8280Bond干燥狀況Nut 粘著力不強(qiáng)8干燥環(huán)境差4自動(dòng)干燥396Bond粘性Nut 粘著力不強(qiáng)9原材料不良3無管理8216點(diǎn)滴方法Nut 粘著力不強(qiáng)5作業(yè)方法無標(biāo)準(zhǔn)化，作業(yè)者品質(zhì)意識(shí)差5無管理71755S1 AssemblyDrive Torque 不良Nut 受力大6Torque 管理不足31 Time/2Shift 點(diǎn)檢6108作業(yè)者方法Nut 受力方向

16、不良5作業(yè)方法無標(biāo)準(zhǔn)化，作業(yè)者品質(zhì)意識(shí)差4100%全檢6120NOV-23-200011SCORING REPORTDATE:2000-11-15Attribute Legend5 (used in computations)NAME:Allied Employee1 passPRODUCT:SFD-321B/*All operators2 failBUSINESS:agree within andAll Operatorsbetween eachagree withOtherstandardKnown PopulationY/NY/NSample #AttributeTry #1Try #2

17、Try #1Try #2Try #1Try #2AgreeAgree1passpasspasspasspasspasspassYY2passpasspasspasspasspasspassYY3passpasspasspasspasspasspassYY4failfailfailfailfailfailfailYY5passpasspasspasspasspasspassYY6passpasspasspasspasspasspassYY7failfailfailfailfailfailfailYY8passpasspasspasspasspasspassYY9failfailfailfailf

18、ailfailfailYY10failfailfailfailfailfailfailYY11passpasspasspasspasspasspassYY12passpasspasspasspasspasspassYY13failfailfailfailfailfailfailYY14passpasspasspasspasspasspassYYOperator #1Operator #2Operator #3Nut 脫落Nut 正常已知的真值已知的真值檢查結(jié)果檢查結(jié)果MNOV-23-200012Statistical Report - Attribute Gage R&R StudyD

19、ATE: 2000-11-15NAME: Allied EmployeePRODUCT: SFD-321B/*BUSINESS:1900-1-0% Appraiser1%Score vs Attribute2SourceOperator #1Operator #2Operator #3Operator #1Operator #2Operator #3Total Inspected141414141414# Matched141414141414False Negative (operator rejected good product)000False Positive (operator a

20、ccepted bad product)000Mixed00095% UCL100.0%100.0%100.0%100.0%100.0%100.0%Calculated Score100.0%100.0%100.0%100.0%100.0%100.0%95% LCL76.8%76.8%76.8%76.8%76.8%76.8%Screen % Effective Score3Screen % Effective Score vs Attribute4Total Inspected1414# in Agreement141495% UCL100.0%100.0%Calculated Score10

21、0.0%100.0%95% LCL76.8%76.8% Notes(1) Operator agrees with him/herself on both trials (2) Operator agrees on both trials with the known standard(3) All operators agreed within and between themselves(4) All operators agreed within & between themselves AND agreed with the known standard% Appraiser0

22、.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%100.0%110.0%Operator #1Operator #2Operator #3% Efficiency95% UCLCalculated Score95% LCL% Score vs Appraiser0.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%100.0%110.0%Operator #1Operator #2Operator #3% Efficiency95% UCLCalculated Score95% LCL檢查人員一致性地檢

23、查人員一致性地評(píng)價(jià)的次數(shù)評(píng)價(jià)的次數(shù)% %檢查人員與真值一致性地檢查人員與真值一致性地評(píng)價(jià)的次數(shù)評(píng)價(jià)的次數(shù)% %檢查人員一致性地檢查人員一致性地評(píng)價(jià)的次數(shù)評(píng)價(jià)的次數(shù)% %與真值一致性地評(píng)價(jià)的次數(shù)與真值一致性地評(píng)價(jià)的次數(shù)% %( (檢查者間檢查者間) )MNOV-23-200013vNut 脫落不良重要影響因素nNut Diameter尺寸；nCarriage Lower 內(nèi)徑尺寸及設(shè)計(jì)n作業(yè)者作業(yè)方法；nNut 壓入Jig 的壓入情況nBond 涂抹量及涂抹均勻度重要因子NOV-23-2000143.903.954.004.054.10LSLUSLProcess Capability Analysis for Nut DiameterUSLTargetLSLMeanSample NStDev (Within)StDev (Overall)CpCPUCPLCpkCpmPpPPUPPLPpkPPM USLPPM TotalPPM USLPPM TotalPPM USLPPM Total4.10000 *3.900003.938561000.01351080.01349282.473.980.950.95 *2.473.990.950.95 0.00 0.00 0.002156.86 0.002156.862131.08 0.002131.08P