T-Flex Yield Improvement By Six Sigma ( ) 1 1/25 Mektec - PowerPoint PPT Presentation

www.mektec.co.th T-Flex Yield Improvement By Six Sigma ( ชื่อบริษัท ) 1 1/25

Mektec Manufacturing Corporation (Thailand) Ltd. 2/25

 Supporting the Global Electronics society. Mektec is the leader of Flexible printed circuits manufacturer, providing to our valuable customer through worldwide sales and manufacturing bases. Space-saving design. Mektec Manufacturing Corporation (Thailand) Ltd. 3/25

Mektec Manufacturing Corporation (Thailand) Ltd. 4/25

Defective Rate all model of GC-assembly on Jun'18 0.35% 100.00% Defect (%) Yield (%) WRK defect top of GC-AS 0.30% 99.50% 0.25% %Defective. 99.00% 0.20% 0.15% 98.50%  WRK. is top defective 0.10% about 0.32% In Jun’18. 98.00% 0.05% 0.32% 0.20% 0.19% 0.18% 0.17% 0.16% 0.10% 0.10% 0.08% 0.07% 0.06%  Model A86 T-Flex is top 0.00% 97.50% WRK OTP OTB FMS PLT OTF FME FNF OTA PLI MRP demand in Jul – Dec’18. A86 T-flex demand 35% of GC-AS Mektec Manufacturing Corporation (Thailand) Ltd. 5/25

In put =1257251 Pcs. GC Top defective rate in Jun'18 Yield = 96.7%. 3.50% Defective rate of WRK = 0.85% 3.00% 2.50% Defectve rate 2.00% 3.28% 3.28% 3.26% 1.50% 2.77% 1.00% 2.01% 1.87% 1.34% 0.50% 0.98% 0.76% 0.00% A86 T-Flex A85 T-Flex E72A DISPLAY A62 U-Flex A72 U-Flex A61 U-Flex A41 T-FLEX A51 D-FLEX A71 U-Flex Product  A86 T-Flex is highest volume in Jul –Dec’ 18.  WRK. is top defective about 0.85% In Jun’ 18. Mektec Manufacturing Corporation (Thailand) Ltd. 6/25

Goal : To improvement each activities more than 70% from base line in defective WRK (1 month). A86 T-Flex WRK by daily on Jun'18 120 1.60% 1.45% 1.40% 1.34% 1.40% 100 1.21% 1.11% 1.10% 1.20% 0.99% 0.98% 80 0.95% 0.94% 0.92% 0.90% 1.00% 0.84% 0.81% 0.79% 0.80% Percent 0.76% Kpcs. 0.75% 0.74% 0.74% 0.73% 60 0.80% 0.68% 0.69% 0.68% 0.68% 0.67% 0.59% 0.58% 0.57% 0.60% 40 70% improve 0.40% 20 0.20% 0 0.00% 16-Jun 1-Jun 2-Jun 3-Jun 4-Jun 5-Jun 6-Jun 7-Jun 8-Jun 9-Jun 10-Jun 11-Jun 12-Jun 13-Jun 14-Jun 15-Jun 17-Jun 18-Jun 19-Jun 20-Jun 21-Jun 22-Jun 23-Jun 24-Jun 25-Jun 26-Jun 27-Jun 28-Jun 29-Jun 30-Jun Date Out Put %WRK Base Line Target In Jun’18 … Found WRK defect at A86 T-flex model average about 0.85%. Target reduce 70% from 0.85% to 0.25% with in ww.33 or reduce 44% from base point. Mektec Manufacturing Corporation (Thailand) Ltd. 7/25

Current status  A86 T-Flex is highest demand of B product from Jun- Dec’ 18.  A86 T-Flex found high WRK defective rate in Jun’ 18 about 0.85%.  GC target reduce 70% from 0.85% to 0.25% with in ww.33. A86 86 T-Fl Flex De Demand and and Co Cost t Sa Saving. Demand Cost saving Cumulative cost saving. 4,000 8,000 6,735 Cost saving plan all project is 3,500 6,137 7,000 6.74 Mthb. 3,000 6,000 4,447 2,500 5,000 KPCS. KTHB. 2,000 4,000 2,988 1,500 3,000 1,744 1,690 1,460 1,244 1,000 2,000 598 500 1,000 - - - - - - Jun Jul Aug Sep Oct Nov Dec MONTH Refer to Demand in Jun’18 Mektec Manufacturing Corporation (Thailand) Ltd. 8/25

Assessment Agreement Date of study: Reported by: Name of product: Misc: Within Appraisers Appraiser vs Standard 100 100 95.0% CI 95.0% CI Percent Percent 95 95 Percent Percent 90 90 85 85 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 Appraiser Appraiser Retrain and Result re-test. No. EN. Effectiveness Miss Rate False Alarm Rate  GR&R for criteria WRK. only. > 95% < 0% < 5%  Re train and retest inspector who not achieved target. 7 14371 100% 0.0% 0.0%  GR&R Test every month. 8 13839 100% 0.0% 0.0% 18 11039 100% 0.0% 0.0% Pass 100% Mektec Manufacturing Corporation (Thailand) Ltd. 9/25

Step 1 Step 2 Step 3 Standardize Short term Long term & Implement improvement improvement for next model  Set standardize and  Apply Automation  Defects analysis Implement for next - Auto FPC set robot. - Repeat again. model. - Auto FCT robot. - Actions by case . - Auto flip tray. Mektec Manufacturing Corporation (Thailand) Ltd. 10/25

Process mapping A86 0.70% 0.60% 0.50% %Defective 0.40% 0.30% 0.59% 0.20% 0.10% 0.14% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% Oven Remov Under Pre- Press Blank# Packin FPC set PSA FCT Final dry e fill blank PSA 2 g  Process mapping summary. 1. Raw mat’l (1.13%) : Before process take action. 2. Pre-blanking (0.14%) : Auto remove , Auto blank and Auto set PSA. 3. FCT (0.59%) : Flip tray , guide out line and method FCT. Focus 2 Process. Mektec Manufacturing Corporation (Thailand) Ltd. 11/25

Root cause Analysis 1. FCT. Load FPCA misalignment with Fixture. Current situation. Fish bone analysis VDO Assumption: Load FPCA Misalignment with Test Fixture effect to WRK. Mapping from NG unit. 2. FPCA bend 0⁰ - <90⁰ after FCT WRK reject. 1.Place in Test Fixture but not fit. 120 ⁰ 90⁰ 45 ⁰ WRK 80% Rej. ACF Area Fixture FCT (Top) ACF area miss position 120⁰ 90⁰ 45 ⁰ FPCA  Next Evaluate working method Fixture FCT (Botton) in action step. Mektec Manufacturing Corporation (Thailand) Ltd. 12/25

Root cause Analysis 2. FCT. FPCA overlap from flip tray. Current design Current situation. Front : tray blank Back : Flip test Assumption : FPCA overlap and jump out from pocket tray effect to WRK. To compare flip tray FPCA overlap vs flip tray FPCA not overlap >> Testing to FCT (FPCA overlap : Warpage ≥ 90 ⁰ ). Compare Defective WRK. 0.54% 0.60% Prepare FPC by 0.50% % Defective. no overlap in 0.40% tray 0.30% 0.20% 0.10% 0.00% 0.00% FPCA hit flip tray. FPCA not hit flip tray. % Defective. Next : Tray improvement in action step. Mektec Manufacturing Corporation (Thailand) Ltd. 13/25

Root cause Analysis 2. Pre-blank Misalignment loading at PSA Fixture and press by cover PSA fixture. Current situation. WRK Compare defective. misalignment 0.14% FPC Sheet move. 0.01% Misalignment Not Misalignment Assumption : Misalignment loading at PSA Fixture effect to WRK. To compare FPCA sheet misalignment load at FPC Set vs Loading correctly. Why Why analysis Misalignment loading. Next : Improve loading to PSA fixture method in action step. Mektec Manufacturing Corporation (Thailand) Ltd. 14/25

Cause Result after test Action  Evaluate working method. Significant 1. FCT : Load FPCA Misalignment with Fixture. Significant  Tray improvement. 2. FCT : FPCA overlap in tray.  Improve loading to PSA fixture Significant 3. Pre Blank : Misalignment method. loading at PSA Fixture and press by cover PSA fixture. Mektec Manufacturing Corporation (Thailand) Ltd. 15/25

 Study loading method to test Fixture. 4  Find out area to pick up FPCA 5 for load to Test Fixture. 3 2 1  Method1 : Pick up area point 1.  Method 4 : Pick up area point 4. 1  Method2 : Pick up area point 2.  Method 5 : Pick up area point 5. 1 Method2 : Control totter ACF area.  Method 3 : Pick up area point 3. Method1 : Can’t find target. Method2 : Significantly. Method3 : No loading target and Ergonomic problem. Method4 : Ergonomic problem and Wrist cuff pick up. Method5 : Significantly. Mektec Manufacturing Corporation (Thailand) Ltd. 16/25

Compare result Method 2 Method 5  We select Sample size 3,200 pcs. Sample size 3191 Significantly Not Significantly ACF area miss position Control totter ACF area Mektec Manufacturing Corporation (Thailand) Ltd. 17/25

 Tray improvement. New design flip tray : Current Flip tray design use 2 side of tray for Flip , New design separate to 2 tray and have 2 step. Compare result New design Compare design 1.10% 1.20% 1.00% % Defective. 0.80% 0.60% 0.40% Blank tray 0.20% 0.00% 0.00% Current design New design %ACF งอ Test flip tray  Design difference pocket height each cavity to avoid ACF damage. Mektec Manufacturing Corporation (Thailand) Ltd. 18/25

1. Problem : No guild pin lock FPC.  Action : Add pin POKAYOKE on set PSA. Compare result Compare Defective WRK. 0.16% 0.14% 0.14% 0.12% % Defective. 0.10% 0.08% 2. Problem : Vacuum pad not enough. 0.06% 0.07%  Action : Add vacuum rain tree from 6 set to 8 set. 0.04% 0.02% 0.00% Current New Current New 3. Problem : Not set STD vacuum force.  Set standard vacuum force (45-85 kPa). Vacuum WRK Drop Can't vacuum Status 40 kPa 0.00% 0.00% 100.00% NG 45-85 kPa 0.00% 0.00% 0.00% OK 90 kPa 37.50% 5.00% 9.00% NG Mektec Manufacturing Corporation (Thailand) Ltd. 19/25

FCT action Pre-blank action Change Tray flip Mektec Manufacturing Corporation (Thailand) Ltd. 20/25