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1、降低降低XXX工序的工序的Detape比率比率 项目背景及来源 根据公司的管理目标，TnR工序每个产品的成本需要降低 至$0.0101/unit，目的是通过降低每个工序的成本从而降 低整个产品的总成本 P1 D C A P4 P3 P2 项目背景及来源 TnR 成本分布成本分布 反工率反工率 (Detape Rate) 材料成本材料成本 主要可控因子主要可控因子 另一个团队在 降低材料成本 P1 D C A P4 P3 P2 现状分析 现有现有TnR工序的工序的detape rate 为为1%, 造成较高的材料耗用与生产周期的浪费造成较高的材料耗用与生产周期的浪费 P1 D C A P4 P3
2、 P2 SIOPC S I P O C Component mfger Cover Tape mfger Carrier Tape mfger Test good, baked, within HIC;clear mark can be read by T machine vision Device Cover tape Carrier tape EIA 481 B EIA 481 B Customer assembly plant MS ESD Label Orientation Quantity Peel Force EIA 481 B Machine set up TnR Part Se
3、lection Peel Force Test Re-inspection QC Gate Pack P1 D C A P4 P3 P2 项目成员及分工 Champion XXX Process Engineer XXX Quality Engineer XXX SQE XXX TnR Shift Supervisor XXX Sr. Equipment Engineer XXX TnR MFG Manager XXX Data and standard Confirmation; QC activity Support Equipment data collection and machin
4、e repair, maintenance actions follow up Manufacture Data collection, and actions follow up Supplier contact, and corrective actions follow up Project improvement actions implementation and source support Communication Regular project review meeting, project status control and summary, data analysis
5、Equipment Engineer XXX P1 D C A P4 P3 P2 项目目标 项目目标是项目目标是2006年年1月底之前降低月底之前降低40%的的TnR工序不良率工序不良率 Base Line 1% Detape Rate Project Goal 0.6% Detape Rate Sep. 2005 Jan. 2006 0.6% 1% P1 D C A P4 P3 P2 项目预期收益 定量目标定量目标 COST COST 金额：金额：100K RMB100K RMB TnRTnR 成本降低成本降低 COST (Money)COST (Money)：XXXXXX XXXXXX $
6、 $ TnRTnR 产能提升产能提升 Output (K)Output (K)：XXXXXXXK/YearXXXXXXXK/Year 财务部核实By: XXXX 基于Detape-rate降低0.4% P1 D C A P4 P3 P2 Y的确立及定义 De-tape Rate=100xDetape reel数量/ 总reel数量 计算公式计算公式: Poor Sealing Foreign Material Tilt Unit Tacked Unit Cover Tape Shift Wrong Orientation Device Chip Mix Unit Wrong Quantity
7、Reference DOC#: EIA-481-B; CTT-141-070 缺陷定义 P1 D C A P4 P3 P2 Y的测量系统分析 Assessment Agreement Appraiser # Inspected # Matched Percent 95 % CI 1 24 22 91.67 (73.00, 98.97) 2 24 22 91.67 (73.00, 98.97) 3 24 21 87.50 (67.64, 97.34) Each Appraiser vs Standard Assessment Agreement Appraiser # Inspected # M
8、atched Percent 95 % CI 1 24 21 87.50 (67.64, 97.34) 2 24 22 91.67 (73.00, 98.97) 3 24 21 87.50 (67.64, 97.34) Between Appraisers Method ;Tape 24 defect sample within one reel, three operators to inspect it twice at speed 2. 分析结果：分析结果：3个操作员的有效性均高个操作员的有效性均高 于于90%，并且方向错误是判断错误的，并且方向错误是判断错误的 主要缺陷主要缺陷 MSA
9、 Efficiency P1 D C A P4 P3 P2 Y的测量系统分析 Attribute Agreement Analysis for Result Within Appraisers Assessment Agreement Appraiser # Inspected # Matched Percent 95 % CI 1 15 15 100.00 (81.90, 100.00) 2 15 15 100.00 (81.90, 100.00) 3 15 14 93.33 (68.05, 99.83) # Matched: Appraiser agrees with him/hersel
10、f across trials. Each Appraiser vs Standard Assessment Agreement Appraiser # Inspected # Matched Percent 95 % CI 1 15 15 100.00 (81.90, 100.00) 2 15 15 100.00 (81.90, 100.00) 3 15 13 86.67 (59.54, 98.34) # Matched: Appraisers assessment across trials agrees with the known standard Between Appraisers
11、 Assessment Agreement # Inspected # Matched Percent 95 % CI 15 13 86.67 (59.54, 98.34) # Matched: All appraisers assessments agree with each other. All Appraisers vs Standard Assessment Agreement # Inspected # Matched Percent 95 % CI 15 13 86.67 (59.54, 98.34) # Matched: All appraisers assessments a
12、gree with the known standard. 分析结果分析结果GR MSAGage R&R P1 D C A P4 P3 P2 Y的测量系统分析 测量系统改进计划测量系统改进计划: 1. 与与QC和生产部门每两周做一次缺陷标准的沟通，借助于缺陷和生产部门每两周做一次缺陷标准的沟通，借助于缺陷 的照片与质量记录数据的照片与质量记录数据.-Lili/ done 2. 降低计数器的最大速度降低计数器的最大速度- Long Hua in 25th Nov/done 3. 长期的改善措施是针对方向错误的缺陷从美国引进自动化检验长期的改善措施是针对方向错误的缺陷从美国引进自动化检验 机器机器
13、-Junxi April 2006 4. 制定缺陷标准照片制定缺陷标准照片- Erpan / Junxi / Lili /done MSA改进计划 P1 D C A P4 P3 P2 Y的测量系统分析 Note: 已经已经20天没有外观判断错误了，因此从天没有外观判断错误了，因此从1月月4日日 开始，不在进行小样本验证开始，不在进行小样本验证 MSAGR&R小样本验证 P1 D C A P4 P3 P2 测量系统分析前后对比 DForeign Material A-Poor Sealing GDouble parts in a pocket KSealing Escape BChip HTap
14、e Damage or Warpage MUnit Tilt FCover Tape Drift ESprocket Hole Damage CWrong Quantity I Trailer and head length J Mark Defect LWrong Orientation NPeel Force Fail O-Others Data collection period: Jan. 2005 to Oct. 2005 Source: TnR MFG Daily Report MSA之前的柏拉图分析 P1 D C A P4 P3 P2 测量系统分析前后对比 DForeign Material A-Poor Sealing GDouble parts in a pocket KSealing Escape BChip HTape Damage or Warpage MUnit Tilt FCover Tape Drift ESprocket Hole Damage CWr
