降低喷漆治具成本DMAIC

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1、1 Team Introduction Opportunity / Business Case / Project Scope Target Setting And Schedule Project Implementation Accomplishments / Results Team Members Of Contact InformationTable of Content2 Team Introduction Opportunity / Business Case / Project Scope - Background - The Introduction Of Painting

2、Process - Project ScopeTable of Content3Industrial pollution damages our environment significantly.Background4Green house effect Icebergs are disappearing. Penguins are looking for home.“I want to go home!”Daddy, where is our home?”“I dont know”.Background5 Our commitment to supporting environmental

3、 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 wasteBackground6The introduction of painting processDuring production：spraying gun sprayAfter production: disassembly products and

4、recycle fixtureCause paints wasteCause fixtures wastePreparation: Assembly of raw parts to fixtureraw-partPaint fixturefinished parts Paint waste used fixtureOutputInput7PAINTS WASTEFIXTURE WASTENeed to recycleAccording to environmental impact RPN evaluation, painting factory conclude to improve:Pro

5、ject ScopeNeed to reduce8 Team Introduction Opportunity / Business Case / Project Scope Target Setting And Schedule Project Implementation Accomplishments / Results Team Members Contact InformationTable of Content91. Reduce the emission of paints by 20%2. Improve fixture recycle times by 50%BeforeAf

6、terAiming for saving of paint usage of the gap between the two parts.Increase fixture recycle period from 2 times to 3 times150mm30mm30mm/150mm=20%Target SettingImprovement After 3X Before 2X 10planactual08-Aug08-Oct 08-Nov 08-Dec 09-Jan 09-FebItemScopeStatus OverviewRoot Cause analysisSolutionData

7、collectionEfficiencyStandardizationPlan Schedule08-Sep11G-ray(Rim Blackberry-8000)Nicole(Sony Ericsson K530i)Jie (Sony Ericsson K630c)Aalto (Nokia N95) Meteor(Rim Blackberry-9000)08-Oct08-Nov08-Dec09-Jan09-FebplanactualProject Schedule08-SepProject name12 Team Introduction Opportunity / Business Cas

8、e / Project Scope Target Setting And Schedule Project Implementation - Reduce Paints Waste - Fixture Recycle TimesTable of Content13Paints WasteManMethodEnvironmentMaterial MachineNot follow SOPInsufficient trainingchange paints mixing ratioWrong fixture designParameter is not correctAir pipe drop o

9、ff Color unstableRaw parts cleanlinessClean room cleanlinessBooth pressure too highBoothTemperature too highBooth Humidity(40%70%) 1.1 Root Cause AnalysisSpray pressure too highPainting Direction FixedFixture cleanliness 1. Reduce Paints Waste 14 1.2 Status Overview 1. Reduce Paints Waste The fixed

10、spraying gun lead to paints wastebetween two spindlesSpray GunVideo = Fix Painting Spray GunCause Paints WasteGap15 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,

11、which will save paint between two parts.16 1.4 Data CollectionPartsQty (PCs)Before Improvement (g/pcs)After Improvement (g/pcs)Improvement (Save) %Total Save (g)PAINTSTHINNERPAINTSTHINNERPAINTSTHINNERPAINTSTHINNERR/H2445451.621.781.2961.42420%20%79219.587042.5B/D2094921.621.781.2961.42420%20%67832.2

12、74531.6Cap bottom2124330.810.890.6480.7220%19%34408.836108.2Total666470/181460197682Paints save 20%Paints reduce in Sep.Take the GAMMA-RAY as an example 1. Reduce Paints Waste 17 1. Reduce Paints Waste GAMMA-RAY R/H B/D & BOTTOM20%GAMMA-RAY R/HGAMMA-RAY B/DGAMMA-RAY BOTTOM1.4 Data CollectionPaints r

13、educe in Sep.unit: g/pcs18 1. Reduce Paints Waste 19Yield rate comparison between robot and fixed gun 1.5 Quality ConfirmationGAMMA-RAY robot painting yield rate in Sep vs fixed painting in Aug. 1. Reduce Paints Waste 201. Reduce Paints Waste Continuous Improvement And Updating BOMUpdating BOM: Pain

14、ts : from 1.62g/pcs to 1.296g/pcs Thinner : from 1.78g/pcs to 1.424g/pcs 21 Statistically we reduced paints 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 Was

15、te 22 2.1 Status Overview 2. Fixture Recycle TimesFixture Quantity (A)94021pcsAssembled Quantity(per fixture) (B)26pcsPainted Quantity (C)4889092pcsRecycle Times (D) A * * BC D=2Aug-2008 G-rays Data 23Insufficient Recycle TimesThe amount of fixture exhaust is big Unit fixture production capacity is

16、lower Less fixture projectsThe fixture machine is well controlledFixture 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 costFit situation is not wellOperation method not well

17、to know Fixture design is un-suitable Hard to assemble the fixture The fixture fees take about 70% Fixture WasteBe lack of education 2.2 Root Cause Analysis 2. Fixture Recycle Times242.3 Solution 2. Fixture Recycle Times Test fixture maximum recycle times Fixtures reworkDecrease fixture usage quanti

18、tyElimination of exhaust emissionIncrease fixture cycle times？25 2.3.1 Test The Maximum Recycle Times Of Fixtures 2. Fixture Recycle Times1.3G-ray Volume Key Bottom Cover Test In Sep. 2008 Scrap %Quality contrastTimesDefectParticleFiberCoveringPaint peelOrange peelGrease Poor CoverageTotal2th1.90.60

19、.20.200.10.13.13th1.90.70.10.20.10.10.13.24th1.80.70.30.20.10.10.13.35th1.90.60.30.30.10.103.36th2.10.70.41.30.30.20.15.17th4.10.51.22.40.20.30.19.326 2.3.2 Fixtures ReworkBefore Without StickerAfter With StickerAdd sticker on the holeExample: G-ray Volume Key Bottom Board Fixture 2. Fixture Recycle

20、 Times Simple rework like adding sticker upon the fixtures will extend the maximum recycle times. .272.3.2. Fixtures ReworkG-ray Volume Key Bottom Cover In Sep. 2008 Scrap % 2. Fixture Recycle Times Quality contrastTimesDefectParticleParticleFiberFiberCoveringCoveringPaint peelPaint peelOrange Orang

21、e peelpeelGrease Grease Poor Poor CoverageCoverageTotal5th 1.80.70.30.20.10.10.13.36th1.90.60.30.30.10.20.13.47th2.20.81.20.40.30.40.35.68th2.81.13.61.20.20.30.39.528The results of the GMMA-RAY fixture improvement Painted quantity(10k)Recycle times(2)*Assembled quantity(26 pcs)= 193 fixtures 193 fix

22、tures * * Weight(0.0202kg)=3.8986kg Weight(0.0202kg)=3.8986kg10K production of Volume Key Bottom Cover as an exampleRecycle times(6)*Assembled quantity(26 pcs)=65 fixtures65 fixtures * * Weight(0.0202kg)=1.3130kg Weight(0.0202kg)=1.3130kg Painted quantity(10k)VSVSReduce 2.5856kg/10KIncrease rate66.3

23、% reach our aimed target(Before)(After)2. Fixture Recycle Times66.3%29 Standardize in WI2. Fixture Recycle Times30 Team Introduction Opportunity/Business Case/Project Scope Target Setting And Schedule Project Implementation Accomplishments / Results Team Members Contact InformationTable of Content31

24、More projects are applying the above-mentioned improvement with different accomplishments.Accomplishments/Results32PartPAINTSFIXTUREBefore (kg)After (kg)Decrease Percent Before (pcs)After (pcs)Decrease PercentBlackberry 80005548443820%67171926861766% Blackberry 90003460198443%1062893542966%K530i6508

25、493724%827475516533%K630i111779628%11944597250%N95106989117%12881704145%Total177021207631%88558034032461% The Results Of The Paints And Fixture Improvement From Sep.08 To Feb.09 Applying projects results: Blackberry 8000, K530i, K630c, N95, Blackberry 9000Accomplishments/Results331.Reduce paints was

26、te by: Tracking Robot2.Reduce material waste by: Increase Fixture Recycle TimesAccomplishments/Results34One World One Jabil One DreamAccomplishments/Results35Im finally home.Beautiful HomelandHey! Lets Have Fun! Thank You JABILLets go swimmingAccomplishments/Results36 Team Introduction Opportunity /

27、 Business Case / Project Scope Target Setting And Schedule Project Implementation Accomplishments / Results Team Members Contact InformationTable of Content37 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.