降低喷漆治具成本DMAIC

Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,Team Introduction,Opportunity / Business Case / Project Scope,Target Setting And Schedule,Project Implementation,Accomplishments / Results,Team Members Of Contact Information,Table of C,ontent,1,Team Introduction,Opportunity / Business Case / Project Scope,- Background,- The Introduction Of Painting Process,- Project Scope,Table of C,ontent,2,Industrial pollution damages our environment significantly.,Background,3,Green house effect Icebergs are disappearing.,Penguins are looking for home.,“I want to go home!”,Daddy,where,is our home?”,“I dont know”.,Background,4,Our commitment to supporting environmental protection of air, water, land, waste and natural resources is, and will remain, a priority for this company.,Environmental Policy,Reduce the paints,waste and material waste,Background,5,The introduction of painting process,During production,：,spraying gun spray,After production:,disassembly products and recycle fixture,Cause paints waste,Cause,fixtures,waste,Preparation:,Assembly of raw parts to fixture,raw-part,Paint,fixture,f,inished parts,Paint,waste,used fixture,Output,Input,6,PAINTS WASTE,FIXTURE,WASTE,Need to recycle,According to,e,nvironmental,impact,RPN,evaluation, painting factory conclude to improve:,Project Scope,Need to reduce,7,Team Introduction,Opportunity / Business Case / Project Scope,Target Setting And Schedule,Project Implementation,Accomplishments / Results,Team Members Contact Information,Table of C,ontent,8,1. Reduce the emission of paints by 20%,2. Improve fixture recycle times by 50%,Before,After,Aiming for saving of paint usage of the gap between the two parts.,Increase fixture recycle period from 2 times to 3 times,150mm,30mm,30mm/150mm=20%,Target Setting,Improvement,After 3X,Before 2X,9,plan,actual,08-,Aug,08-Oct,08-Nov,08-Dec,09-Jan,09-Feb,Item,Scope,Status Overview,Root Cause analysis,Solution,Data collection,Efficiency,Standardization,Plan Schedule,0,8-Sep,10,G-ray,(Rim Blackberry-8000),Nicole,(Sony Ericsson,K,530i),J,ie (Sony Ericsson,K,630c),A,alto (Nokia N95),Meteor,(Rim Blackberry-9000),08-Oct,08-Nov,08-Dec,09-Jan,09-Feb,plan,actual,Project Schedule,08-Sep,Project name,11,Team Introduction,Opportunity / Business Case / Project Scope,Target Setting And Schedule,Project Implementation,-,R,educe,Paints Waste,-,Fixture Recycle Times,Table of C,ontent,12,Pa,ints,W,aste,Man,Method,Environment,Material,Machine,Not follow SOP,Insufficient training,change paints,mixing ratio,Wrong fixture,design,Parameter is,not correct,Air pipe,drop off,Color,unstable,Raw parts,cleanliness,Clean room,cleanliness,Booth pressure,too high,Booth,Temperature,too high,Booth,Humidity,(40%70%),1.1 Root Cause Analysis,Spray pressure,too high,Painting,Direction,Fixed,Fixture,cleanliness,Controlled,Without control,1.,Reduce Paints Waste,13,1.2 Status Overview,1.,Reduce Paints Waste,The fixed spraying gun lead to paints waste,between two spindles,Spray Gun,Video = Fix Painting Spray Gun,Cause Paints Waste,Gap,14,1.3 Solution,Robot Spay Painting,1.,Reduce Paints Waste,Robot spray gun,can reduce,the problem of,paints waste,Video of,Painting,robot,Each spray gun track a single spindle and spray, which will save paint between two parts.,15,1.4 Data Collection,Parts,Q,ty (PCs),Before Improvement (g/pcs),After,Improvement (g/pcs),Improvement (,Save,) %,Total Save (g),PAINTS,THINNER,PAINTS,THINNER,PAINTS,THINNER,PAINTS,THINNER,R/H,244545,1.62,1.78,1.296,1.424,20%,20%,79219.5,87042.5,B/D,209492,1.62,1.78,1.296,1.424,20%,20%,67832.2,74531.6,Cap bottom,212433,0.81,0.89,0.648,0.72,20%,19%,34408.8,36108.2,Total,666470,/,/,/,/,/,/,181460,197682,Paints save 20%,Paints reduce in Sep.,Take the GAMMA-RAY as an example,1.,Reduce Paints Waste,16,1.,Reduce Paints Waste,GAMMA-RAY R/H,B/D &,BOTTOM,20%,GAMMA-RAY R/H,GAMMA-RAY B/D,GAMMA-RAY BOTTOM,1.4 Data,Collection,Paints reduce in Sep.,unit: g/pcs,17,Quality?,1.,Reduce Paints Waste,18,Yield rate comparison between robot and fixed gun,1.5 Quality Confirmation,GAMMA-RAY,robot painting yield rate,in Sep vs,fixed painting in Aug.,1.,Reduce Paints Waste,Very close yield rate !,19,1.,Reduce Paints Waste,Continuous,I,mprovement,A,nd,U,pdating BOM,Updating BOM: Paints : from 1.62g/pcs to 1.296g/pcs Thinner : from 1.78g/pcs to 1.424g/pcs,20,S,tatistically,we,reduced paint,s,waste with robot,spray gun,to reach our target, while,maintaining,good,product quality at the same time,.,Next we will,introduce how to,improve the fixture recycle times,.,1.,Reduce Paints Waste,21,2.1 Status Overview,2. Fixture Recycle Times,Fixture Quantity (A),94021pcs,Assembled Quantity,(per fixture) (B),26pcs,Painted Quantity (C),4889092pcs,Recycle Times (D),A,*,B,C,D=,=2,Aug-2008 G-ray,s Data,Less fixture recycle times resulted,large quantity fixture waste,22,Machine,Man,Methods,Environment,Material,Insufficient Recycle Times,The amount of fixture exhaust is big,Unit fixture production capacity is lower,Less fixture projects,The fixture machine is well controlled,Fixture surface is dirty,Storage environment is dirty,Fixture supplier quality control is not well,Without the declare of reducing the cost,The lower conscious of reducing fixture cost,Fit situation is not well,Operation method not well to know,Fixture design is un-suitable,Hard to assemble the fixture,The fixture fees take about 70%,Fixture Waste,Be lack of education,2.2 Root Cause Analysis,2. Fixture Recycle Times,Controlled,Without Control,23,2.3 Solution,2.,Fixture,Recycle Times,Test fixture,maximum,recycle times,Fixtures,rework,Decrease fixture usage quantity,Elimination of exhaust emission,Increase fixture cycle times,？,？,？,24,2.3.1 Test The Maximum Recycle Times Of Fixtures,2.,Fixture Recycle Times,1.3,G-ray Volume Key Bottom Cover Test In Sep. 2008 Scrap %,Quality contrast,Times,Defect,Particle,Fiber,Covering,Paint peel,Orange peel,Grease,Poor Coverage,Total,2th,1.9,0.6,0.2,0.2,0,0.1,0.1,3.1,3th,1.9,0.7,0.1,0.2,0.1,0.1,0.1,3.2,4th,1.8,0.7,0.3,0.2,0.1,0.1,0.1,3.3,5th,1.9,0.6,0.3,0.3,0.1,0.1,0,3.3,6th,2.1,0.7,0.4,1.3,0.3,0.2,0.1,5.1,7th,4.1,0.5,1.2,2.4,0.2,0.3,0.1,9.3,25,2.3.2 Fixtures Rework,Before Without,Sticker,After With,Sticker,Add sticker on the hole,Example: G-ray Volume Key Bottom Board Fixture,2.,Fixture,Recycle Times,Simple rework like adding,s,ticker upon the fixtures will,extend the maximum recycle times,.,26,2.3.2. Fixtures Rework,G-ray Volume Key Bottom Cover In Sep. 2008 Scrap %,2.,Fixture,Recycle Times,Quality contrast,Times,Defect,Particle,Fiber,Covering,Paint peel,Orange peel,Grease,Poor Coverage,Total,5th,1.8,0.7,0.3,0.2,0.1,0.1,0.1,3.3,6th,1.9,0.6,0.3,0.3,0.1,0.2,0.1,3.4,7th,2.2,0.8,1.2,0.4,0.3,0.4,0.3,5.6,8th,2.8,1.1,3.6,1.2,0.2,0.3,0.3,9.5,27,The results of the GMMA-RAY fixture improvement,Painted quantity(10k),Recycle times(2),*,Assembled quantity(26 pcs),=,193 fixtures * Weight(0.0202kg)=3.8986kg,10K production of Volume Key Bottom Cover as an example,Recycle times(6)*Assembled quantity(26 pcs),=,65 fixtures,* Weight(0.0202kg)=1.3130kg,Painted quantity(10k),VS,Reduce,2,.5856kg/10K,Increase rate66.3%,reach our,aimed target,(,Before,),(,After,),2.,Fixture,Recycle Times,66.3%,28,Standardize in WI,2.,Fixture,Recycle Times,29,Team Introduction,Opportunity/Business Case/Project Scope,Target Setting And Schedule,Project Implementation,Accomplishments / Results,Team Members Contact Information,Table of C,ontent,30,More projects are applying the above-mentioned improvement with different accomplishments.,Accomplishments/Results,31,Part,PAINTS,FIXTURE,Before (kg),After (kg),Decrease Percent,Before (pcs),After (pcs),Decrease Percent,Blackberry 8000,5548,4438,20%,671719,268617,66%,Blackberry 9000,3460,1984,43%,106289,35429,66%,K530i,6508,4937,24%,82747,55165,33%,K630i,1117,796,28%,11944,5972,50%,N95,1069,891,17%,12881,7041,45%,Total,17702,12076,31%,885580,340324,61%,The,R,esults,O,f,T,he,P,aints,A,nd,F,ixture,I,mprovement,F,rom,Sep.08,T,o Feb.09,Applying projects results: Blackberry 8000, K530i, K630c, N95, Blackberry 9000,Accomplishments/Results,32,1.Reduce paints waste by:,Tracking Robot,2.Reduce material waste by: Increase Fixture Recycle Times,Accomplishments/Results,33,One World,One,Jabil One Dream,Accomplishments/Results,34,I,m finally home.,Beautiful Homeland,Hey! Lets Have Fun! Thank You JABIL,Lets go swimming,Accomplishments/Results,35,Team Introduction,Opportunity / Business Case / Project Scope,Target Setting And Schedule,Project Implementation,Accomplishments / Results,Team Members Contact Information,Table of C,ontent,36,Thank you,The resource is limit, while the value we can create is unlimited. We are obligated to make good use of the limited resource to create more value.,37,