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1、GPBI08011GPBI08011降低降低GP1022L15GP1022L15高内阻开路高内阻开路报废率报废率V60SBDHTWU200809V60SBDHTWU2008091717Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率目录定義定義測量測量分析分析提高提高控制控制2Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率定 義3Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率Project Ch
2、arter4Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率Back Group GP1022L15的報廢類型主要有低OCV、高delta OCV、高RI/開路。因有GB項目改善1865L220低OCV 問題，可以應用到該型號的低OCV 問題；另有BB項目改善1865L220高delta OCV問題，也可以應用到此型號的delta OCV問題。因此，選擇GP1022L15高內阻/開路作为改善項目5Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率Back Group
3、 镭射工序假焊引起的GP1022L15高RI/开路的比率占高RI/开路比率的90%以上6Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率Project Plan7Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率測 量8Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率流程图JR工序工序CP装配装配EP工序工序GP工序工序半成品電池放入夾具下顶放入夹具凹槽上顶放入夹具凹槽扣紧镭射夹具进行镭射取出已镭射半
4、成品加底介子入杯加顶介子碰底车坑加沥青加密封圈焊下顶啤Vent Line上下顶镭射焊接外观检查套密封圈9Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率鐳射工序鐳射工序SIPOCP 将电池下将电池下顶放入镭射顶放入镭射夹具凹槽夹具凹槽将上顶放入将上顶放入镭射夹具凹镭射夹具凹槽槽夹具压紧上夹具压紧上下顶下顶 将夹具與将夹具與電池放入镭電池放入镭射机进行上射机进行上下顶镭射下顶镭射取出已镭射取出已镭射电池电池I人员操作人员操作机器参数机器参数電池半成品電池半成品来料来料（KPIV）上頂來料上頂來料夾具夾具作业指导书作业指导书控制计划
5、控制计划S上顶供应商上顶供应商下顶啤下顶啤VENT LINE工序工序O 镭射半成镭射半成品好品电池品好品电池鐳射假焊電鐳射假焊電池池 YsC 套密封圈套密封圈 工序工序 KPOVs（Ys)=鐳射假焊電池鐳射假焊電池10Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率鐳射工序輸入輸出分析鐳射工序輸入輸出分析11Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率高高RI/开路开路C&E矩阵图矩阵图FMEA分析12Six sigma green belt project：
6、降低降低GP1022L15高高RI/开路报废率开路报废率高高RI/开路开路C&E矩阵图矩阵图通過C&E矩阵图分析，影響高RI的主要因素在鐳射工序FMEA分析13Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率高高RI/开路开路FMEA鐳射機參數不當(頻率、脈寬、脈高)，計劃通過DOE分析，找出產生高RI的CTQ頂組合問題，計劃改變頂組合設計，將頂組合更改為下頂包上頂方式14Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率Measure Plan:DOERemark
7、 : np 5p = 1.4%n = 358pcs15Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率R&R Study:RI檢查檢查(Spec.:130mohm190mohm)Source VarComp (of VarComp)Total Gage R&R 0.5516 0.89 Repeatability 0.1870 0.30 Reproducibility 0.3646 0.59 Operator 0.0357 0.06 Operator*Part 0.3289 0.53Part-To-Part 61.5917 99.
8、11Total Variation 62.1433 100.00 Study?Var %Study?Var %ToleranceSource StdDev (SD) (6?*?SD) (%SV) (SV/Toler)Total Gage R&R 0.74270 4.4562 9.42 7.43 Repeatability 0.43246 2.5947 5.49 4.32 Reproducibility 0.60381 3.6229 7.66 6.04 Operator 0.18885 1.1331 2.40 1.89 Operator*Part 0.57352 3.4411 7.28 5.74
9、Part-To-Part 7.84804 47.0882 99.56 78.48Total Variation 7.88310 47.2986 100.00 78.83Number of Distinct Categories = 14結論：%Study Var 在10%以下，%Tolerence 在10%以下，且信賴區間不重疊數大于5，表明 Gage R&R 合格16Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率分 析17Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率
10、开路报废率測量結果18Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率測量結果分析結論：通過結論：通過DOE分析，頻率、脈寬和脈高都不是影響高分析，頻率、脈寬和脈高都不是影響高RI的關鍵輸入因子的關鍵輸入因子 Factorial Fit: RESULT versus 頻率頻率 , 脈寬脈寬 , 脈高脈高 Term Effect Coef SE Coef T PConstant 0.4738 0.2213 2.14 0.278頻率 -0.0625 -0.0312 0.2213 -0.14 0.911脈寬 -0.0625 -0.03
11、13 0.2213 -0.14 0.911脈高 -0.3175 -0.1588 0.2213 -0.72 0.604頻率 *脈寬 -0.0625 -0.0312 0.2213 -0.14 0.911脈寬 *脈高 0.1825 0.0913 0.2213 0.41 0.751頻率 *脈寬 *脈高 -0.0675 -0.0337 0.2213 -0.15 0.904S = 0.625790 R-Sq = 43.44% R-Sq(adj) = 0.00%Analysis of Variance for RESULT (coded units)Source DF Seq SS Adj SS Adj M
12、S F PMain Effects 3 0.217237 0.217238 0.072413 0.18 0.8972-Way Interactions 2 0.074425 0.074425 0.037213 0.10 0.9173-Way Interactions 1 0.009112 0.009112 0.009112 0.02 0.904Residual Error 1 0.391613 0.391613 0.391613Total 7 0.69238819Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率上下頂分析上下頂錯
13、位 從投影圖片看到，上下頂有錯位20Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率上下頂分析 在壓頂與封口工序，頂組合錯開，密封圈上的瀝青滲入上下頂之間，引起高RI或RI不穩定21Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率舊下頂圖紙22Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率新下頂圖紙下下頂頂包包上上頂頂設設計計23Six sigma green belt project：降低降低G
14、P1022L15高高RI/开路报废率开路报废率改 進24Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率新舊頂組合實驗比較頂組合類型不合格数好品数不合格率舊頂組合1210141.17%新頂組合210190.20%Test and CI for Two Proportions Sample X N Sample p1 12 1014 0.0118342 2 1019 0.001963Difference = p (1) - p (2)Estimate for difference: 0.0098716195% CI for dif
15、ference: (0.00268222, 0.0170610)Test for difference = 0 (vs not = 0): Z = 2.69 P-Value = 0.007Fishers exact test: P-Value = 0.007Chi-Square Test: 壞品數壞品數 , 好品數好品數 壞品數 好品數 Total 1 12 1014 1026 7.02 1018.98 3.538 0.024 2 2 1019 1021 6.98 1014.02 3.556 0.024Total 14 2033 2047Chi-Sq = 7.143, DF = 1, P-Va
16、lue = 0.008P-Value 0.05，說明新頂說明新頂組合能夠明顯改善高組合能夠明顯改善高RI25Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率新舊頂組合實驗比較(驗證)頂組合類型不合格数好品数不合格率舊頂組合1510091.46%新頂組合210470.19%Test and CI for Two Proportions Sample X N Sample p1 15 1024 0.0146482 2 1049 0.001907Difference = p (1) - p (2)Estimate for differ
17、ence: 0.012741995% CI for difference: (0.00492418, 0.0205595)Test for difference = 0 (vs not = 0): Z = 3.19 P-Value = 0.001Fishers exact test: P-Value = 0.001Chi-Square Test: 壞品數壞品數 , 好品數好品數 壞品數 好品數 Total 1 15 1009 1024 8.40 1015.60 5.191 0.043 2 2 1047 1049 8.60 1040.40 5.067 0.042Total 17 2056 207
18、3Chi-Sq = 10.344, DF = 1, P-Value = 0.001P-Value 0.05，說明新頂說明新頂組合能夠明顯改善高組合能夠明顯改善高RI26Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率新舊頂組合實驗比較(驗證)頂組合類型不合格数好品数不合格率舊頂組合1810321.71%新頂組合310550.28%Test and CI for Two Proportions Sample X N Sample p1 18 1032 0.0174422 3 1055 0.002844Difference = p
19、(1) - p (2)Estimate for difference: 0.014598395% CI for difference: (0.00598914, 0.0232074)Test for difference = 0 (vs not = 0): Z = 3.32 P-Value = 0.001Fishers exact test: P-Value = 0.001Chi-Square Test: 壞品數壞品數 , 好品數好品數 壞品數 好品數 Total 1 18 1032 1050 10.46 1039.54 5.435 0.055 2 3 1055 1058 10.54 1047
20、.46 5.394 0.054Total 21 2087 2108Chi-Sq = 10.938, DF = 1, P-Value = 0.001P-Value 0.05，說明新頂說明新頂組合能夠明顯改善高組合能夠明顯改善高RI27Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率改善結果 由I階段的實驗分析表明，新頂組合對高RI比率有明顯的改善，量產效果有待進一步跟進ItemBeforeAfterZ-ST3.74.2DPMO14000ppm3000ppmHigh RI defect rate1.4%0.3%CpK1.231.42
21、28Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率財務收益直接收益直接收益: :HK$80,000 =150Kpcs*(1.4%-0.3%)*1000*4.04*12間接間接收益收益: :推廣并應用到其他型號推廣并應用到其他型號:GP1029L20GP1015L08GP0820L07GP0836L1529Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率控 制今后所有圓柱10系列量產時，頂組合全部換用新頂30Six sigma green belt project：降低降低GP1022L15高高RI/开路报废率开路报废率Thanks !31结束！结束！
