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

SLIDE 1

(ชื่อบริษัท) 1

T-Flex Yield Improvement

www.mektec.co.th

1/25

By Six Sigma

SLIDE 2

Mektec Manufacturing Corporation (Thailand) Ltd. 2/25

SLIDE 3

Mektec Manufacturing Corporation (Thailand) Ltd.

 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.

3/25

SLIDE 4

Mektec Manufacturing Corporation (Thailand) Ltd. 4/25

SLIDE 5

Mektec Manufacturing Corporation (Thailand) Ltd.

0.32% 0.20% 0.19% 0.18% 0.17% 0.16% 0.10% 0.10% 0.08% 0.07% 0.06% 97.50% 98.00% 98.50% 99.00% 99.50% 100.00% 0.00% 0.05% 0.10% 0.15% 0.20% 0.25% 0.30% 0.35% WRK OTP OTB FMS PLT OTF FME FNF OTA PLI MRP %Defective.

Defective Rate all model of GC-assembly on Jun'18

Defect (%) Yield (%)

A86 T-flex demand 35% of GC-AS WRK defect top of GC-AS

 WRK. is top defective about 0.32% In Jun’18.  Model A86 T-Flex is top demand in Jul – Dec’18.

5/25

SLIDE 6

Mektec Manufacturing Corporation (Thailand) Ltd.

3.28% 3.28% 3.26% 2.77% 2.01% 1.87% 1.34% 0.98% 0.76% 0.00% 0.50% 1.00% 1.50% 2.00% 2.50% 3.00% 3.50% 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 Defectve rate Product

GC Top defective rate in Jun'18

In put =1257251 Pcs. Yield = 96.7%. Defective rate of WRK = 0.85%

 A86 T-Flex is highest volume in Jul–Dec’18.  WRK. is top defective about 0.85% In Jun’18.

6/25

SLIDE 7

Mektec Manufacturing Corporation (Thailand) Ltd.

1.45% 0.90% 1.34% 0.79% 1.11% 0.74% 0.57% 1.10% 0.68% 0.99% 0.67% 0.95% 0.98% 0.75% 0.81% 0.84% 1.40% 1.21% 0.76% 0.68% 0.73% 0.68% 0.58% 0.92% 0.69% 0.94% 0.59% 0.80% 0.74% 0.00% 0.20% 0.40% 0.60% 0.80% 1.00% 1.20% 1.40% 1.60%

20 40 60 80 100 120

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 16-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

Percent

Kpcs.

Date

A86 T-Flex WRK by daily on Jun'18

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. Goal : To improvement each activities more than 70% from base line in defective WRK (1 month). 70% improve

7/25

SLIDE 8

Mektec Manufacturing Corporation (Thailand) Ltd.

1,244

1,460 1,690 598

1,744

2,988 4,447 6,137 6,735

1,000

2,000 3,000 4,000 5,000 6,000 7,000 8,000

500

1,000 1,500 2,000 2,500 3,000 3,500 4,000

Jun Jul Aug Sep Oct Nov Dec

KTHB. KPCS. MONTH

A86 86 T-Fl Flex De Demand and and Co Cost t Sa Saving.

Demand Cost saving Cumulative cost saving.

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.

Cost saving plan all project is 6.74 Mthb. Refer to Demand in Jun’18

8/25

SLIDE 9

Mektec Manufacturing Corporation (Thailand) Ltd.

> 95% < 0% < 5% 7 14371 100% 0.0% 0.0% 8 13839 100% 0.0% 0.0% 18 11039 100% 0.0% 0.0% No. EN. Effectiveness Miss Rate False Alarm Rate

Retrain and Result re-test.  GR&R for criteria WRK. only.  Re train and retest inspector who not achieved target.  GR&R Test every month.

Pass 100%

Date of study: Reported by: Name of product: Misc: 2 1 9 1 8 1 7 1 6 1 5 1 4 1 3 1 2 1 1 1 9 8 7 6 5 4 3 2 1 100 95 90 85 Appraiser Percent 95.0% CI Percent 2 1 9 1 8 1 7 1 6 1 5 1 4 1 3 1 2 1 1 1 9 8 7 6 5 4 3 2 1 100 95 90 85 Appraiser Percent 95.0% CI Percent

Assessment Agreement

Within Appraisers Appraiser vs Standard

9/25

SLIDE 10

Mektec Manufacturing Corporation (Thailand) Ltd.

Short term improvement Long term improvement

Standardize & Implement for next model

Defects analysis
Repeat again.
Actions by case .
Apply Automation
Auto FPC set robot.
Auto FCT robot.
Auto flip tray.
Set standardize and

Implement for next model.

Step 1 Step 2 Step 3

10/25

SLIDE 11

Mektec Manufacturing Corporation (Thailand) Ltd.

0.00% 0.00% 0.00% 0.00% 0.14% 0.00% 0.00% 0.00% 0.59% 0.00% 0.00% 0.00% 0.10% 0.20% 0.30% 0.40% 0.50% 0.60% 0.70% %Defective

Process mapping A86

Oven dry FPC set Remov e Under fill Pre- blank PSA Press PSA Blank# 2 FCT Final Packin 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.

11/25

SLIDE 12

Mektec Manufacturing Corporation (Thailand) Ltd.

Assumption: Load FPCA Misalignment with Test Fixture effect to WRK.

Root cause Analysis

1. FCT. Load FPCA misalignment with Fixture.

Fish bone analysis

VDO Current situation.

1.Place in Test Fixture but not fit. ACF area miss position

2. FPCA bend 0⁰- <90⁰ after FCT WRK reject.

90⁰ 120⁰ 45⁰

WRK

FPCA

Fixture FCT (Botton) Fixture FCT (Top)

90⁰ 120⁰ 45⁰

Mapping from NG unit.

80% Rej. ACF Area

 Next Evaluate working method in action step.

12/25

SLIDE 13

Mektec Manufacturing Corporation (Thailand) Ltd.

Assumption : FPCA overlap and jump out from pocket tray effect to WRK.

Root cause Analysis

2. FCT. FPCA overlap from flip tray.

Current situation. To compare flip tray FPCA overlap vs flip tray FPCA not overlap >> Testing to FCT (FPCA overlap : Warpage ≥ 90⁰).

0.54% 0.00% 0.00% 0.10% 0.20% 0.30% 0.40% 0.50% 0.60% FPCA hit flip tray. FPCA not hit flip tray.

% Defective.

Compare Defective WRK.

% Defective.

Prepare FPC by no overlap in tray

Back : Flip test

Current design

Front : tray blank

Next : Tray improvement in action step.

13/25

SLIDE 14

Mektec Manufacturing Corporation (Thailand) Ltd.

Root cause Analysis

2. Pre-blank Misalignment loading at PSA Fixture and press by cover PSA fixture.

Current situation. Assumption : Misalignment loading at PSA Fixture effect to WRK. To compare FPCA sheet misalignment load at FPC Set vs Loading correctly.

FPC Sheet move.

misalignment WRK

Why Why analysis Misalignment loading.

0.14% 0.01% Misalignment Not Misalignment

Compare defective.

Next : Improve loading to PSA fixture method in action step.

14/25

SLIDE 15

Mektec Manufacturing Corporation (Thailand) Ltd.

Cause Result after test Action

1. FCT : Load FPCA Misalignment

with Fixture. Significant  Evaluate working method.

2. FCT : FPCA overlap in tray.

Significant  Tray improvement.

3. Pre Blank : Misalignment

loading at PSA Fixture and press by cover PSA fixture. Significant  Improve loading to PSA fixture method.

15/25

SLIDE 16

Mektec Manufacturing Corporation (Thailand) Ltd.

 Find out area to pick up FPCA for load to Test Fixture.

3

5

4 1

2

 Study loading method to test Fixture.

Method1 : Pick up area point 1.
Method2 : Pick up area point 2.

Method1 : Can’t find target. Method2 : Significantly. Method3 : No loading target and Ergonomic problem. Method4 : Ergonomic problem and Wrist cuff pick up. Method5 : Significantly.

Method2 : Control totter ACF area.

Method 3 : Pick up area point 3.
Method 4 : Pick up area point 4.
Method 5 : Pick up area point 5.

1 1

16/25

SLIDE 17

Mektec Manufacturing Corporation (Thailand) Ltd.

 We select Sample size 3,200 pcs.

Sample size 3191

Compare result

Control totter ACF area ACF area miss position

Significantly Not Significantly

Method 2 Method 5

17/25

SLIDE 18

Mektec Manufacturing Corporation (Thailand) Ltd.

 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.

Blank tray Test flip tray

New design

 Design difference pocket height each cavity to avoid ACF damage.

1.10% 0.00% 0.00% 0.20% 0.40% 0.60% 0.80% 1.00% 1.20% Current design New design

% Defective.

Compare design

%ACF งอ

Compare result

18/25

SLIDE 19

Mektec Manufacturing Corporation (Thailand) Ltd.

2. Problem : Vacuum pad not enough.

 Action : Add vacuum rain tree from 6 set to 8 set.

1. Problem : No guild pin lock FPC.

 Action : Add pin POKAYOKE on set PSA.

0.14% 0.07%

0.00% 0.02% 0.04% 0.06% 0.08% 0.10% 0.12% 0.14% 0.16%

Current New % Defective.

Compare Defective WRK.

Current New

Compare result

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

19/25

SLIDE 20

FCT action Pre-blank action Change Tray flip

Mektec Manufacturing Corporation (Thailand) Ltd. 20/25

SLIDE 21

Mektec Manufacturing Corporation (Thailand) Ltd.

Refer :

TI-PIN-1063 (Pre-blank) TI-PIN-1254 (Tray&FCT)

ตารางตรวจสอบความพร้ อมก่อนเริ่มท าการผลิต MODELA86 T-Flex OPERATION : ตัว อย่าง DATE / MONTH 6 / 7

LINE NO.

JC1 M/C. NO. 08 SHIFT A TIME 1430 MODE CS 1 Vacuum pad Arm pick up FPC 8 Set ดูที่ vacuum arm O หรือ X OPERATOR O 2 Vacuum pad Arm pick up FPC 8 Point ดูต าแหน่งที่ vacuum arm ดูด FPC O หรือ X OPERATOR O 3 Pin on base FPC set 4 Pin ดูจ านวน Pin ที่ Base O หรือ X OPERATOR O 4 Vacuum value 45 to 85 kPa ดูหน้าจอก าหนดลม O หรือ X OPERATOR x 4 Machine safety ปุ ่ ม Emergency ปุ ่ ม Emergency ต ้ องอยู่ในสภาพไม่แตกหัก เมื่อกดปุ ่ มเครื่องต ้ องหยุดท างาน ทันที O หรือ X OPERATOR O 5 PM Over Due PM ต ้ องไม่ Over Due ดูที่สติ๊กเกอร์ PM O หรือ X OPERATOR O CHECK BY EN NO. OPERATOR B456 CHECK BY EN NO. TECHNICIAN B123 JUDGEMENT BY OKหรือNG OK DAILY AUDIT BY EN NO. B100 WEEKLY AUDIT BY Signature PROD MGR QA Audit Acc / Rej QA Auditor A หรือ R ASSIS SUPV / SUPV. DAILY CHECK SHEET Auto set PSA OPERATION CODE : 3420 M/C NAME : YEAR : NOTE : รายการ จุดตรวจสอบ ข ้ อก าหนด วิธีตรวจสอบ วิธี บันทึกค่า ระเบียบปฏิบัติ/ ขั้นตอนการปฏิบัติ (Methodology) In-process tray flip มี 2 แบบ คือ In-process tray blanking และ In-process tray FCT

1. ให ้

ใช ้ Code MPCT 054A (Blank) และ code MPCT 054B (FCT) (ยกเลิกใช ้ code MPCT 029)

2. ท ำกำร flip tray โดยกำรจับด ้ำนข ้ำงของ tray แล ้วพลิก tray กลับด ้ำนเพื่อให ้

ตัวงำนมำอยู่ที่ Tray FCT

3. ใช ้

Vacuum pen จับตัวงำนบริเวณจุดกึ่งกลำงของ FPCA (ใต ้ shim)

4. Load งำนเข ้ำ fixture FCT โดยให ้

กะระยะจำก Outline เมื่อ FPC ชิดกับ Outline ด ้ำนหลังแล ้วให ้ ปล่อยงำนลง โดยไม่ต ้องกดตัวงำนลงไป เพื่อหลีกเลี่ยงกำรชนของ ACF In-process tray Blanking: MPCT A In-process tray FCT: MPCT B Logo Mektec Old design code : MPCT 029 pick up Outline Outline

21/25

SLIDE 22

Mektec Manufacturing Corporation (Thailand) Ltd.

Before After

1. Auto FPC set robot.
2. Auto FCT robot.
3. Auto flip tray.

22/25

SLIDE 23

Mektec Manufacturing Corporation (Thailand) Ltd.

 Cost saving.

1744 2988 4447 6137 6735

1,330 4,273 5,802 7,226 9,139 10,017

2000 4000 6000 8000 10000 12000 Jul'18 Aug'18 Sep'18 Oct'18 Nov'18 Dec'18

Saving KThb. Month.

Cost saving.(KThb)

Plan Actual Cum Plan Saving Cum Actual Saving

In Jul-Dec’18 saving cost about 10 MThB.

Δ +10.0 MThB (Jul-dec’18).

Start

23/25

SLIDE 24

Mektec Manufacturing Corporation (Thailand) Ltd.

0.44% 0.69% 0.61% 0.63% 0.60% 0.62% 0.74% 0.00% 0.11% 0.10% 0.10% 0.23% 0.17% 0.23% 0.00% 0.10% 0.20% 0.30% 0.40% 0.50% 0.60% 0.70% 0.80%

100 200 300 400 500 600

ww.23 ww.24 ww.25 ww.26 ww.27 ww.28 ww.29 ww.30 ww.31 ww.32 ww.33 ww.34 ww.35 ww.36 % Kpcs.

A85T-flex : Monitor WRK

Out Put %WRK. Target

1st expand to model A85 T-flex.

We can reduce WRK defective of A85 T-Flex from 0.60% in Jun’18 to less than

0.25% in Aug’18.

Stop build change Design.

24/25

SLIDE 25

Q & A

25/25