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PROJECT SCOPE

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.

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PROJECT SCOPE

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  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 • 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 • 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 -- 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

  7. LESSONS LEARNED • 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!

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