1. 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

2. 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.

3. 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.

4. 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

5. 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.

6. 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 min.
Demonstrated set up time min.
Saving of 40 min per set up. (80% saving)
Annual Saving:
40min * 10 setup/day * pcs/Hr * RMB 0.02 * 365 days = US$ 101,572

7. 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!