PROJECT SCOPE Scope : SMT Machine in both plant I and plant III.

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Presentation transcript:

PROJECT SCOPE Scope : SMT Machine in both plant I and plant III. Project Objectives : Improve the Productivity of SMT Eliminate the bottleneck of the whole line Reduce the set up time Keywords: Eliminate Non-value added activities, Quick changeover

PROJECT DESCRIPTION Observe the SMT Change Over operation on site. Video-tape the process of SMT set-up for further analysis. Break down the set up process and identify waste. Team brain storming for waste elimination activities. Work out the future change over time. Work out action plans Implementation and result testing.

CURRENT SITUATION APS Location : P3-1F M/C: SAMSUNG Model : EES PSU48-C11A Total Changeover time over 3 Hrs Observation poor planning material not placed in sequential order programmer not ready for set-up ( not notified ) poor management & organizing too little manpower to load the feeders work instruction not being used until 2hrs later. Operator not sure of next step.

CURRENT SITUATION lots of waste poor preparation reels/ Material too far away from machine no pre-adjust feeders for large integrated circuits lots of waste tools /equipment too far away from machine Many tasks can be done when machine still running Unnecessary movement,waiting,repairing

IMPROVEMENT PLAN Improve planning & preparation Waste elimination Setup team with 2 more operators Check material & program in advance Standardize job assignment and sequence to each member Waste elimination Load & unload feeder by using a U shape cell Redesign a moveable set up station Keep inventory record for all the feeders & related tools/equipment Better feeder maintenance Pre-load material in sequence at the U shape cell. Use spare cover (for feeder) Reduce unnecessary movement Target changeover time from 180 mins. to 40 mins.

SMT Kaizen Results – Set Up Reduction Location : P1-1F (Machine #: MSH2) Purpose : Reduce set up time at Bottleneck Machine to increase capacity for entire plant Observation Set up team are in proper position. Each setup team member know their own task well. Material well prepared and can be plug in immediately. Little unnecessary movement. Result : March 26 set up time record -- 50 min. Demonstrated set up time -- 10 min. Saving of 40 min per set up. (80% saving) Annual Saving: 40min * 10 setup/day * 21000 pcs/Hr * RMB 0.02 * 365 days = US$ 101,572

LESSONS LEARNED Waste always exists. Team work brings many good ideas. Management commitment and attention is important Waste always exists. Team work brings many good ideas. Operators can tell you all the details about the process. There is always room for continuous improvement. Good planning and preparation is essential. GO AHEAD AND TAKE ACTION TODAY!