Task: Reduce the SMD components reject rate from 0.45% to 0.3% for whole line.
Result: Got the reject rate 0.33%.
Save 0.42million Euro in one year.
FPY improve 1.5%.
Define:
This project is mainly focus on reduce the components placement machine either due to special cause – monthly maintenance, technical, material issue, or the common cause – daily control procedure.
SIPOC（图表 略）
Measure
The on time evaluation system – MaDaMaX is the tool for measurement all components reject for each station and line. It can identify the component reject caused by Vacuum error or Identification error.（系统截图 略）
According to this record, a cost based measurement is created twice a shift.（跟踪表 略）
The dot plot and process mapping measure the problem in the process and organization field.
（流程图 略）
Analyze
The process related issue is analyzed by using the tool:
-Process mapping
-Box plot
-ANOVA test
To find out the root cause and find out whether after process change the result have significant difference or not.
The critical components related issue is analyzed by using the tool:
-Pareto chart
-Two sample T test
Analyze is mainly execute by compare the reject rate form the same component but delivered by different supplier or by different equipment, different package description.
（流程图，parato，T－test等图表 略）
Improve
After the new process implemented in Monthly Maintenance process, the large variance for reject has been reduced and closely monitored.
The improvement of critical components had been executed via
-Technical way – optimize GF, Nozzle, Feeder for different suplier
-Organizational way – special monitoring when change new supplier
-Contact QZ for improvement form Supplier Side.
Control
Two sample for the compare of the reject rate Before and After.（图略）
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