The application of the dmaic techniques for business Performances case study for open defect of single-sided Flexible circuit board
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Date
2018-05-23
Authors
Chua, Khai Shen
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Abstract
Manufacturing company all around the world are facing the turbulent economic
condition. This include global competition, customer demand for high quality product
and reduced in lead time. In respond this need, various tools and tehniques have been
developed. The lean principles tools are one of the strategies developed to enhance
productivity and quality performance. One of the lean technique is the DMAIC. It is a
methodology to solve the defect problem to increase the effectiveness and efficiency
of the business performances is through “Continuous Process Improvement”. DMAIC
is a data improvement cycle designed to applied on business process to find flaw or
inefficiencies- particularly resulting in output defect. The target of this project is to reduce the open defect for the circuit on the
Flexible Printed Circuit Board from 0.57% to 0.4% by implementation of DMAIC. From the record of Visual Inspection Yield Report, it is found that the Open defect is
the main problem on the flexible printed circuit board. The part number (13236) has
been choosen as the highest open defect problem for the research main focus. For this
study, Imaging area will be the main focus because it is related to the process
formation of the circuit. The main two causes on imaging area are Contamination
problem and Pin Hole. Hence the Six Sigma DMAIC methodology are initiated by
problem identification through the past record of the open defect. Then, the
specification data of existing flexible printed circuit board are gathered. This is
followed by the analysis and improvement steps, the tools such as trend chart, Cause-effect diagram. Then, evaluation form are distributed to understand the root
cause of the process. At improvement and control phase, a series of solution
(Checklist and standardisation ) are presented. With the implementation of the DMAIC solution, the result observed from January
2017 until January 2018, has shown that the overall open defect has decrease from
0.6%(17781 unit) decrease to 0.37%(4766 unit). While the part (13236) that have the
highest defect also decrease from 0.68% (2644 unit) to 0.26% (132 unit). After the
improvement were conducted, the total accumulated saving cost from September
2017 till March 2018 are RM 1423.60. This can help company to increase the profit
margin in the long term.