QCC Curly team

Closing report

Prepare By: CH Wong and Norasmadi

Content
1.0

Introduction................................................................................................. 3

1.1
Background of the Study .................................................................................... 3
1.1.1
History of QCC Curly team ........................................................................ 3
1.1.2
Review of the QCC Curly Studies .............................................................. 4
1.2
QCC Curly Team 2010 ....................................................................................... 5
1.2.1
Background of QCC Curly Team (2010).................................................... 5
1.2.2
Objective and Target................................................................................... 8
1.2.3
QCC Curly Team Organization Chart ........................................................ 8

2.0

Frame work of study................................................................................... 9

2.1
Effectiveness for previous QCC Curly Study..................................................... 9
2.2
Root cause analysis ........................................................................................... 13
2.3
Proposal of improvement.................................................................................. 15
2.3.1
Create "On Hold" tag for curly wire ......................................................... 15
2.3.2
Create and conduct Survey ....................................................................... 15
2.3.3
Review & check RWD SOP & WI versus current practical at RWD
section 16
2.3.4
Pulley out of alignment checking at all RWD machine............................ 16
2.3.5
Tension arm vibration checking and verification ..................................... 16
2.3.6
Monitor wire break in RWD section......................................................... 16
2.3.7
Conduct Awareness training to RWD operator ........................................ 16

3.0

Activity and Implementation ................................................................... 17

3.1
Gantt chart for QCC curly team........................................................................ 17
3.2
Implementation ................................................................................................. 18
3.2.1
Questionnaire and Survey for training...................................................... 18
3.2.2
Evaluation of machine variation on end tension verification ................... 21

4.0

Result and conclusion ............................................................................... 25

4.1
Result ................................................................................................................ 25
4.1.1
Effectiveness of Awareness Training. ...................................................... 25
4.1.2
The Effectiveness of Machine Tension Modification............................... 25
4.2
Conclusion ........................................................................................................ 29

5.0

Appendix .................................................................................................... 33

1.0 Introduction
1.1 Background of the Study
1.1.1 History of QCC Curly team
Since 2000 years, the first QCC Curly team was established to eliminate curly
issue which is lead by KS Ong, activities still been carried on to monitor the reoccurrence
of the abnormality. From the pass studies, QCC Curly team have clarified the few types
of the Curly that observe as shown in Appendix 1, type A is known as spiral curl, type B
as wavy curl and type C as entangled curl. Quote by previous QCC Curly report, QCC
Curly team had identified different major root-cause that will cause 3 different type of
curly and all the criteria mainly occurred at the final stage of production process, thus all
the action is mainly focus in the last stage of the process -Rewinding section .Table 1
have shown the different curly types causes,

Type
A

B
C

Cause
Wire entwine at tension arm
Wire entangle at tension weight

Action
Fix high friction rubber at
tension arm

Methodology
Semi MistakeProofing

Wire caught at cable tier head

Installation of tension box cover

Wire mis-setting and hang at

tension arm pulley shaft

Grind protruded pulley shaft

Semi MistakeProofing
Semi MistakeProofing

Wire hang at small radius object

like cable tier, counter cover,
tension weight, etc.
Wire out of pulley during
rewinding process

Installation of tension arm pulley

sensor on Rewinding mc

MistakeProofing

Installation of tension arm

pulley sensor at Rewinding

MistakeProofing

Loose wire at annealed product

Improper handling of annealed
product

Annealing operators are urged to

handle annealed product spool
horizontally.

Training

Annealed product shall not be

rewound in backward direction of
winding rotation.

Training

Lost of wire source due to spring

back effect at annealed product
Sticky wire

Real time checking before

rewinding
Table 1: QCC-Curly team (2000) Root Cause and action

Training

1.1.2 Review of the QCC Curly Studies

A lot of analysis and evaluation been done by QCC Curly team. Refer to
Appendix 2, process FMEA have be done to analyses the main root cause of curly. The
team had concluded that, Rewinding Machine is one of the major contributions to the
curly issue. The QCC Curly team has suggested divide the team to 3 different groups:-

1) Training group:
The main role for the Training group is to create and suitable syllabus of training material
which related to the potential curly issue and method to reduce curly. A questionnaire in
Appendix 3 been distribute to Rewinding Operator to examine the knowledge about
curly. Base on the questionnaire and study from QCC Curly team, the new procedure and
awareness been create, QCC Curly training group will prepare the training schedule to
conduct the training and educated existing operator or new operator, and all the training
material and procedure can refer to Appendix 4.
2) Improvement Group :
Refer to the Appendix 5, many simulation study have been done by QCC Curly team
simulate the actual problem which will cause the curly occur in production. Main role of
QCC Curly Improvement group is conducting test and evaluated the abnormality of the
Curly. The QCC Curly Improvement group has classified 3 different of curly and base on
different type of curly and machine modification had been done to reduce the curly risk
occur on the machine. Action been verified, and majority of the action have success and
curly issue have reduce a lot since 2001 years after the QCC Curly established.
3) Audit Group
After the new procedure for curly had been established, QCC Curly Audit group
functional to ensure operation is standardized in production. To ensure the stability of the
long run process, QCC Curly has to judge and consults productions run smoothly refer to
Appendix 6. Monitoring process will continuous until target achieves which is curly is
fully eliminated.

From the previous study, QCC curly team has reduce the reject frequencies from
1.6 times claim monthly to 0.14 time claim monthly, and the improving percentage of
reducing customer complaint is high, which is 91% improvement.

Customer Complaint Curly

4

Before Improvement

After Improvement

Cases

3
2
1
0
Apr May June Jul

Aug Sep Oct Nov Dec Jan Feb Mar

Apr May June Jul

Aug Sep Oct Nov Dec

Month

Graph 1: Customer complaint April 2000 to Dec 2001

1.2 QCC Curly Team 2010

1.2.1 Background of QCC Curly Team (2010)
Although the effectiveness have been done during the first stage by QCC Curly,
in 2003, curly issue increasing and second high contribution to the customer complaint,
which is 8 cases over 21 cases, 38.1 %. It falls back again to 4 cases for the second year
2004 , but it still consider high while the percentage is 23.5% . In 2006 and 2007 , thats
no any customer complaint due to curry issue, for 2008, year curly not contribute too
much the customer complaint which is 1 case. In 2009, curly issues suddenly increase to
3 cases. From the observation of the trend, customer claim due to curly issue will
continue increase, if action not need taken to tackle the problem

Defect

2003

2004

2005

2006

2007

2008

2009

Sticky

Curly

Loose

Spool Glue

Wrong tape colour

Entanglement

Wrong wire type label

Wrong spl color

Wrong label

Wrong carton box label color

Wire loop deform problem

Spl case dirty

EFO Opened

Ball size problem

Foreign Material

21

17

Total

Table 2: Defect customer complaint from 2003 to 2009

Customer Claim by Year vs Defects Category

F o re ign M a te ria l
B a ll s ize pro ble m

24

EF O Ope ne d

21

S pl c a s e dirty
Wire lo o p de fo rm pro ble m

18

Wro ng c a rto n bo x la be l c o lo r

15

Wro ng la be l
Wro ng s pl c o lo r

12

Wro ng wire type la be l

Enta ngle m e nt

Wro ng ta pe c o lo r
S po o l Glue

Lo o s e

C urly

2003

2004

2005

2006

2007

2008

2009

S tic ky

Ye ar

Graph 2: Customer Claims by Years VS Defects Categories

The Graph 2 show that, in 2009 curly is the major contribute to the customer
claim, which there are 3 different customer had claimed the same defect , RIST, UTAC
DG (ASAT DG) and Panasonic Singapore.

No

RMA

Description

R912-008

RIST claimed Au wire was found twist before

used in production, which suspected may lead
to abnormal wire loop and 1st neck break.
2 spools are detected of total 216 spools
shipped in that lot.

R911-003

ASAT-DG claimed found wire is curling

when released during set up process. The internal
pressure has not yet released completely.
Total 200 spools shipped for that particular shipment
lot and one spool is found rejected.

R907-008

Feedback from customer (Panasonic Singapore) on

1) Wire curling up is seen on "NG" wire lot.
2) Product using "NG" wire shown curvy looping

Table 3: Valid CAR related to Curly 2009

In 2010, MEM been detected at least 31 lots sticky issue, 13 source missing, and
curly issue in the production. Most of the defect possible cause by curly which is base on
the previous study, even though internally SPA not show curly defect is the most defect
internally, but the similar effect with different defect still in the increasing trend.

Hence curly may continues increase gradually,

Graph 3: Pareto by defect internal SPA 2009

1.2.2 Objective and Target

The main objective of the New QCC Curly Team is:
1) To eliminate the curly issues against in MEM
This objective setup to maintain the previous QCC Curly team objective to continues
improvement to process vise, and eliminate abnormality (curly) inside the production.
2) Zero Customer complaint on Curly issues
MEM put customer at the first priority to achieve customer satisfaction. MEM having
continues improvement plan to reduce customer complaint, in the hand to maintain the
business in the win- win situation.
Target:
0 curly issues in MEM and customer side

1.2.3

QCC Curly Team Organization Chart

Advisor

SC Puah
Leader
CH Wong

Secretary
Salmiah

QA
Norita

Process
Engineering
Faridah

Production
Suzila

Production
Azri

Figure 1: QCC Curly Team Organization Chart

The new QCC Curly team is supervised by SC Puah, senior QA Manager, and lead by
CH Wong from QA/QC with multi-disciplinary from different department, Secretary
Miss Salmiah from QA, members, Faridah from Process Engineering, Suzila and Azri
which is from Production. Please refer Appendix 7

2.0 Frame work of study

2.1 Effectiveness for previous QCC Curly Study
In pass of the study, most of the previous QCC curly team studies mainly focus on
machine modification improvement, training, and auditing (verification). The verification
effectiveness were not continues to monitoring, after a years. Mean while, changes of the
environment and other improvement, is shift to the lost focus of curly issue. Without the
data proving, the significant of the previous study may become the doubts to the top
management continue to invest, while the comment of the ROI is the most important
issue.
QCC Curly team have review back the action been taken, and verified the present
status of the action. As we know that, curly have divided to few categories, and by focus
on different type of curly, previous team have come out different action and solution
target on different type curly.

Table 4: Verification the action for Previous QCC Curly team

Detail from table 4 show that, the verification table for previous action which
been done by QCC-Curly. From the current implementation, friction rubber has been
removed from the machine this is because friction rubber is not contributed very much to
the process improvement after the monitoring. The installation of the friction rubber had
causes another defect after the few time monitoring, expecially dust can stick on the
friction rubber and potentially drop to body wire, when Rewinding process.

There are no more pulley shaft grinded to avoid the wire hang at pulley shaft, the
latest pulleys been modified without grinded and replace with cap cover, to cover the
shaft from the pulley (figure 2).

Figure 2: Grind pulley shaft been switch to cover cap

To reduce the curly defect, working procedure been carried on and studied by
QCC Curly standardized the process of checking method. To remove waving curl cause
by curl removed failure during drawing, for all process operator required remove the curl
follow the 3 type curly criteria spiral curl, waving curl, and entanglement curl. Operator
should handled annealed product spool horizontally and hook the wire 3 circle on the
screw (Appendix 7)
Type C or we call entangle curl type while it cause by irregular winding in
rewinding process. It also can caused by spring back effect when Rewinding operator cut
off start source of Annealing mother spool after pasted end tape. Entangled Annealing
spool is wound onto Rewinding spool by incorrect path. The friction between entangled
wire sources with adjacent layer will cause curl wire. Figure 3 show the phenomena of
entanglement happen in Rewinding process

10

Figure 3: Entanglement phenomenon Source wire (red) slipped through adjacent

layer

Figure 4: Hold the wire source, before cut the wire (to prevent wire spring back)

For current practice, operator ought to be hold Annealing spool end wire source
after end tape pasted on spool flange prior to cut the wire source for rewinding process
completion. The tension apply on the wire will cause the start tape source spring back if
cut without hold. A new entanglement checking method been implement in Rewinding
section, operator need will need to hold wire horizontally and observe the annealing spool
mother lot no entangling.

11

Figure 5: Reconfirm the entanglement wire.

For each wire setup up, rewinding operator required to do curl check to ensure
wire in the curl acceptance criteria.

Figure 6: Curl check for wire setting

12

2.2 Root cause analysis

QCC- Curly team is looking toward to study the potential failure in rewinding
process which will be causes the curly issue. Potential cause of curly wire been determine
by using cause and effect analysis to analysis which is majority causes will contribute the
highest curly defect in rewinding process.
Potential causes are divided to the 4 main categories that will cause the curly
defect, material, machine, method and man. Material is the causes that due to product or
material itself either from supplier (previous process) or nature characteristic of the
material. Machine is normally is the machine variation, accessories, alignment setting and
capability of the machine. Method is the standard of setting, instruction, procedure and
process handling. Man will be human behavior, mistake, attitude, awareness and
competency.
In rewinding process, material that been transfer from the previous process is
Annealing product lot. Normally annealing lot will check again by QCIP to ensure wire
in good condition and transfer to the next process rewinding. For those wires sticky and
loose wires which contribute to curl defect can be detected while doing the QCIP
checking. Wires sticky and loose wires will remove if detected, but if the entangle wire is
at the inner layer for the spool, QCIP unable check the wire by visual checking on the
first layer.
From previous QCC-Curly team, they had done a lot of modification for the
Rewinding machine to reduce the curly issue. From the result, it had showed the
successful of QCC-Curly team reduced a lot of curly due to rewinding machine. But we
still look into possible causes of the machine, although some of the action had been
propose before and done it. For rewinding machine, spool not proper fix at the take up
and pay off, potential cause curly, but stated in procedure, rewinding personnel should
check the spool properly before start run. Some of the possible cause like out of
alignment and vibration sensor malfunction will cause the wire curly, and maintenances
personal have monitor and check it frequently. From loose issue claim, we found out that
our machine tension is not consistent, and it have contribute to loose issue a few times, as
we know that, if a particular machine tension is not consistent , it will be a uncontrolled
vibration and possible wire curl on that particular machine.

13

To avoid wire curly flow to customer side, we had implemented curl check follow
the 3 criteria, entanglement check to detect the curly while setting the wire. Our QCCCurly team members observed the rewinding operator, and make sure that they
implement curl check and entangle check when doing wire setup. Our rewinding operator
been brief to few action example like pull or twist the wire during set up and to hold the
wire during end taping process after finish rewinding, all the action been observed too by
QCC- Curly members when the time doing the verification study.
The competency of man kind is one of the potential causes too, while different
man kind will have different characteristic. We have come out a few assumptions that
human mistake that can cause curl defect in the process like they not follow procedure
which documented, not check curl on Mother Lot, ignorance of vibration sensor and so
on. And maybe some of them is new still not use to be the process, and not aware for the
defect.

Figure 7: Fish Bone Analysis for Wire curly

14

From the figure 7, we have concluded 3 possible major causes that would be
contribute the curly to the product:1) Tension not consistent
2) Tension arm vibration
3) Mother lot entanglement

2.3 Proposal of improvement

Team has decide to propose a few action to improve existing process and achieve
team objective to eliminate the curly issue against in MEM and zero customer complaint
on Curly issues:
2.3.1 Create "On Hold" tag for curly wire
A new process had created for immediate action while abnormality product occurred at
rewinding process:
Found abnormality wire during RWD process
by RWD staff

Inform to SO, leader & above

RWD staff issue SPA & email to Curly Team

Further verification by Curly Team

2.3.2 Create and conduct Survey

To know well the operator competency to their related process (Rewinding
process), team decide to create a survey form to survey and get the feedback from them.

15

From the survey form, we will know how much operator know much about curly issue.
(Refer to Appendix 8)
2.3.3

Review & check RWD SOP & WI versus current practical at

RWD section
The objective for the action is to compare current practice to current SOP &
working instruction is similar. For the current practice are different from SOP & working
instruction, will review again by the team to make sure current procedure still suitable to
the current process. (Refer to Appendix 9)

2.3.4 Pulley out of alignment checking at all RWD machine

Co-operate with engineering maintenances to check any out of alignment for
machine, and 3 months monitoring for the machines to know the trend of alignment
checking. It helps to know the frequencies out of pulley happen for each rewinding
machine.

2.3.5 Tension arm vibration checking and verification

Co-operate with process engineering to initialize all tension of the machines to
default, and re- tuning again the machines. Verification been done by process engineering
and Calibration to verify all the tension within the specification, and categories for certain
range of diameters in different group of machines.

2.3.6 Monitor wire break in RWD section

Monitor wire break in production for RWD machine, to get the data and analyst
any abnormality for the wire. Suspected some of the machines were stop due to wire
entanglement, wire sticky, which can cause curly wire inside the production.

2.3.7 Conduct Awareness training to RWD operator

Conduct awareness training to RWD operator regarding to the analysis from the
survey form. Enhance existing process to reduce the wire reject due to curly wire. Add on
new method to detect curly when operation in RWD machine.
16

3.0 Activity and Implementation

3.1 Gantt chart for QCC curly team

Figure 8: Gantt chart for QCC curly activities

17

3.2 Implementation
3.2.1 Questionnaire and Survey for training
To establish a suitable training material, QCC-Curly team have create questionnaire
form to survey the current practice inside the production and to know the competency of
RWD operator to do checking for curly wire, 8 question been create and overall answer
are correct.

18

19

1) Apakah itu curly dan lukiskan jenis curly yang anda tahu

100%

Betul semua

20

Figure 9: Result from Questionnaire.

3.2.2 Evaluation of machine variation on end tension verification

Study been carried on in-cooperate with Process Engineering and Calibration to
verified the actual tension for Rewinding machine. QCC-Curly team suspected one of
the rootcause come from the stability of tension to cause the Curly issue, and machine
tension should check thoroughly. We had compared the result of end tension last
layer and end stop tension from the panel (PLC result) with Gauge (actual) result.

21

(Refer Appendix 10). By using the winding condition of 158 with the tension setting
2.2g, set count 630, a verification been done for all the machine.
End Tension Last Layer-Machine Indication
6

Tension (g)

5
4
Line A
Line B

Line C

2
1
0
1

9 10 11 12 13 14 15 16 17 18 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
M achine

Graph 4: End Tension Last Layer-Machine Indication

End Tension Last Layer-Gauge Indication
6

Tension (g)

5
4
Line A
Line B

Line C

2
1
0
1

9 10 11 12 13 14 15 16 17 18 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Machine

Graph 5: End Tension Last Layer- Machine Indication

Stop Tension - Machine Indication
6

Tension (g)

5
4
Line A
Line B

Line C

2
1
0
1

9 10 11 12 13 14 15 16 17 18 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
M achine

Graph 6: Stop Tension Machine indication

22

Stop Tension - Gauge Indication

6

Tension (g)

5
4
Line A
Line B

Line C

2
1
0
1

9 10 11 12 13 14 15 16 17 18 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
M achine

Graph 7: Stop Tension - Gauge Indication

From the result show that, RWD machine lines C from no 23 to 42 is lower than
the others machine compare with machine line A and machine line B. The End tension (g)
last layer for machine line C no 23 to 42 is within 1.2g to 4.1 g compare to end tension (g)
result accordingly to gauge is 1.5g to 4.4g. The result is much lower than machine line A
and machine line B which is the result is within 1.7g to 5.3g. Compared with the stop
tension for machine line A, line B and line C, same result show that machine line C no 23
to 42 is much more lower than machine line A and line B, which the result of mean is
rounded 2.0g machine line C, 4.0g for machine line A and line B. Stop tension for gauge
is much more higher than stop tension on machine indicator, maximum tension (g) for
machine line A and line B is 5g, and machine line C is 4.2.
From the result, the stability of the tension is under the spec control, process
engineer and Calibration advice to reset again the tension of the each machine to
segregate machine to tension to 3 categories,
Tension
Initial tension >= 3.5g

Machine Quantity
5 mc

Initial tension 1.9 ~ 3.4

29 mc

Initial tension <=1.8g

6 mc

Table 4: Segregation for rewinding machine Tension setting

And the schedule of RWD machine calibration and tension Board Adjustment been come
out to overcome the issue of instability tension.

23

Type
PC98
PC98
PC98
PC98
PC98
PC98
PC98
PC98
PC98
PC98
PCAT
PC98
PC98
PC98
PC98
PC98
PC98
PC98
PC98
PC98
PC98
PCAT
PCAT
PCAT
PCAT
PCAT
PCAT
PCAT
PCAT
PCAT
PCAT
PCAT
PCAT
PCAT
PCAT
PCAT
PCAT
PCAT
PCAT
PCAT

Machine

item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42

tension set max ten capability

>=3.5g
7g
>=3.5g
7g
<=1.8g
3.5g
<=1.8g
3.5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
>=3.5g
7g
>=3.5g
7g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
<=1.8g
3.5g
<=1.8g
3.5g
<=1.8g
3.5g
<=1.8g
3.5g
>=3.5g
7g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g
1.9 ~ 3.4g
5g

April
wk4

Modification schedule
May
wk1
wk2
wk3

Remarks
wk4
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed
completed

Plan
Completed

Table 5: Schedule Rewinding Machine Calibration and Tension Board Adjustment

24

4.0 Result and conclusion

4.1 Result
4.1.1 Effectiveness of Awareness Training.
Base on the result of questionnaire, QCC-Curly team have design training
material and training have been done when inventory. (Appendix 11) .Attendance please
refer to (Appendix 12).
4.1.2 The Effectiveness of Machine Tension Modification
After the modification by Process Engineering and Calibration, end tension and
stop tension shows better result for all 3 lines initial tension<= 1.8 g and 1.9g ~ 3.4g. For
categories >= 3.5g, PC 98 machines shows slight variation compared to PCAT which is
more stable (Figure 18, 19, 20, 21). The tension for PC 98 is difficult to control and need
to always to the tension board adjustment as compared to PCAT which is PLC control.
Further monitoring for PC 98 machine will done by Maintainers engineering and Process
Engineering to ensure the machine is smooth and stable.

Graph 8: End tension last layer for <=1.8 g

25

Graph 9: End tension last layer Gauge for <=1.8g

Graph 10: End Stop Tension Machine <=1.8g

Graph 11: End Stop Tension Gauge <=1.8g

26

Graph 12: End tension last layer for 1.9g ~ 3.4g

Graph 13: End tension last layer Gauge for 1.9g ~ 3.4g

Graph 14: End Stop Tension Machine for 1.9g~3.4g

Graph 15: End Stop Tension Gauge for 1.9g ~ 3.4g

27

Graph 16: End tension last layer for >= 3.5g

Graph 17: End Tension Last Layer Gauge for >= 3.5g,

Graph 18 Stop Tension for >= 3.5g,

28

Graph 19: Stop Tension Gauge for >= 3.5g,

4.2 Conclusion
Since Jan 09, Curly defect is one of the famous defects that are happen internally
and externally. Before QCC-Curly setup, there are 6 issue related to curly defect in
production, 5 customer complaint. All are detected in rewinding process checking or
claim from customer. After QCC-curly team setup in 2010 February, curly defect have
reduce to 0 compare to 2009. QCC-curly team has monitored the curly defect and
continues improve the process which will cause the defect of curly.

Curly defect before & after set up activities

5
# curly
After set up
activities

# SPA

Before set up activities

1.Collect curly data 2009~2010

2.Team investigate on curly occur at
production
3. Switch off vibration M/C problem

0
Jan- Feb- Mar- Apr- May- Jun- Jul- Aug- Sep- Oct- Nov- Dec- Jan- Feb- Mar- Apr- May- Jun- Jul- Aug- Sep- Oct09
09
09
09
09
09
09
09
09
09
09
09
10
10
10
10
10
10
10
10
10
10

Graph 20: Curly defect before & after set up activities

29

Curly summ. by section

# issue SPA

2009

2010

0
DWG

ANL

RWD

QAO

Graph 21: SPA (Curly) 2009/2010 by section

Curly summ. Before & after set up
5
2009

2010

# SPA

4
3
2
1
0
# SPA

Graph 22: SPA (Curly) before and after setup

Curly sum issuanc e by spool status
# prd spool

# ANL spool

0
2009

2010

Graph 23: SPA (Curly) issuance by spool status

30

Curly sum by status

Waive

Reject

0
2009

2010

Graph 24: SPA (Curly) waive and reject status

External CAR from customer

RMA -No

Customer

Defects Description

Itemcode

Received
Complaint Date

RF00275JPN

23/07/09

R4K0246JAG

10/11/09

RGS0485BR1

23/12/09

RGS0485BR1

22-01-10

RGS0485BR1

01-02-10

Customer Complaint

R907-008

Panasonic
(S)

R911-003

Asat DG

R912-008

RIST

R1001-002 &

ROHM
APOLO

R1002-001

ROHM
APOLO

1) Wire curling up is seen on "NG"

wire lot. 2) Product using "NG" wire
shown curvy looping.
ASAT-DG claimed found wire is
curling when released during set up
process. The internal pressure has
not yet released completely. Total
200 spools shipped for that particular
shipment lot and one spool is found
rejected.
RIST claimed Au wire was found twist
before used in production, which
suspected may lead to abnormal wire
loop and 1st neck break. 2 spools are
detected of total 216 spools shipped
in that lot.
RIST claimed Au wire was not flowed
well due to wire twist before used in
production, which suspected may
lead to abnormal wire loop and 1st
neck break. Primary sampling check
by QC detected same defect. 2
spools are detected of total 228
spools shipped in that lot
RIST claimed Au wire was not flowed
well due to wire twist before used in
production, which suspected may
lead to abnormal wire loop and 1st
neck break. Primary sampling check
by QC detected same defect. 2
spools are detected of total 228
spools shipped in that lot.

Table6: Customer complain 2009~2010

31

Yearly Curly com plaint from Custom er

5

3
2009
2010
2

0
Customer Complaint

Graph 25: Yearly complaint from customer 2009/2010

Montly total valid claim
2

Claim

Before set up activities

After set up activities

Total

0
Jan09

Feb09

Mar09

Apr09

May09

Jun09

Jul09

Aug- Sep09
09

Oct09

Nov09

Dec09

Jan10

Feb10

Mar10

Apr10

May10

Jun10

Jul10

Aug- Sep10
10

Oct10

Month

Graph 26: Monthly total valid claim from customer 2009~2010

In order to eliminate the cause and effect from the curly, all the activities will
continue and monitor the progress by QCC-curly team. Of course, from time to time, the
training and new method will updated accordingly for betterment of both Quality and
Quality of our products to achieve our vision 0 curly issues in MEM and customer
side

32

5.0 Appendix
Appendix 1
Type A

Type B

Type C

33

Appendix 2
POTENTIAL FAILURE MODE AND EFFECT ANALYSIS ( PROCESS FMEA )
Item : Cover at Tension Arm

Process
Function
Setting wire

Potential
Failure
Mis-setting

Mishandling

Loose Wire

Potential Effect
of Failure
Hang at weight

Sev

Class Potential Causes

Occ

Current Process Control

Det

RPN

Recommended Action

Action Taken
Occ Det
RPN
1
1
5

Did not properly done

Re-set wire

160

Re-set wire

Sev
5

Hang at shaft

Due to c/bench air blow

Re-set wire

128

Re-set wire

24

Hang at pulley cap

Did not see

Re-set wire

192

Re-set wire

192
40

Hang at cable tier

Due to c/bench air blow

Re-set wire

96

Change direction & use thread

Hang at stopper

Did not properly done

Re-set wire

16

Re-set wire

Touch wire with finger

Finger

QAO to decide

168

Consult QAO

168

Touch wire with tweezer

Do in fast pace

Scrap

144

Holding only spool or tweezer

144

Touch case when packing

Did not use proper

procedure

Scrap

126

Follow procedure

126

Drop

Rough handling

Scrap

24

Training

24

Tension variation

TBA

Adjustment

48

Adjustment

48

Spool holder loose

Did not place spool

correctly
Loose spring
High friction

Place properly

200

Check after place spool

200

2
1

Change spring/holder
Apply PM

6
7

96
63

Freq PM compare to previous

Freq PM compare to previous

8
9

2
1

4
5

64
45

Traverse not smooth

RPN Before Action

1461

RPN After Action

1085

POTENTIAL FAILURE MODE AND EFFECT ANALYSIS ( PROCESS FMEA )

Item : Tension Board Adjustment

Process
Potential
Function
Failure
Tension BoardTension Arm
Adjustment Vibrate

Potential Effect
of Failure
Loose wire

Sev
10

Class Potential Causes

Tension vibrate hard

Occ
5

Current Control
Process
Redo TBA

Det

RPN

Recommended Action

200

Redo TBA

Sev
7

Action Taken
Occ Det
RPN
4
4
112

Sticky wire

10

Tension too high

Reduce tension reading

250

Redo TBA

Curly wire

10

Vibrate too freq and hard

Redo TBA

80

Redo TBA

10

80

Wire break during RWD

Vibrate too freq and hard

Redo TBA

128

Redo TBA

96

Entanglement to ANL
spool

Vibrate too freq and hard

Redo TBA

128

Redo TBA

128

RPN Before Action

786

RPN After Action

140

556

POTENTIAL FAILURE MODE AND EFFECT ANALYSIS ( PROCESS FMEA )

Item : High Friction Rubber at Tension Arm

Process
Function
Setting wire

Potential FailurePotential Effect

of Failure
Wire touch Normal curly
shaft
Heavy curly
Scratch

Sev
6

Class Potential Causes

Wire touch rubber/shaft

Occ
5

Current Process
Control
Scrap wire

Wire touch rubber/shaft

Wire touch rubber/shaft

Det

RPN

120

Scrap Wire

180

Scrap Wire

180

RPN Before Action

Recommended Action
Install rubber, wire break when
touch rubber
Install rubber, wire break when
touch rubber
Install rubber, wire break when
touch rubber

480

Sev
6

Action Taken
Occ Det
RPN
4
2
48

72

72

RPN After Action

192

POTENTIAL FAILURE MODE AND EFFECT ANALYSIS ( PROCESS FMEA )

Item : Tension Arm Pulley Sensor at ANL Machine

Process
Potential
Potential Effect
Function
Failure
of Failure
Setting Wire Out of pulley at Scratch
tension arm

Sev

Class Potential Causes

Occ

Current Control Process

Det

RPN

Recommended Action

Action Taken
Occ Det RPN
3
3
81
3
3
81

Due to out of pulley

Touch sensor

5
3

Scrap the wire

Scrap the wire

4
4

180
108

Install sensor & m/c stop auto

Install sensor & m/c stop auto

Sev
9
9

Curly wire

10

Out of pulley
Touch air knife

5
5

Scrap the wire

Scrap the wire

4
4

200
200

M/c stop after sensor detection

Install sensor at air knife

10
10

3
3

3
3

90
90

Wire break

10

Material issue
Tension too high
Anl temp too high

4
3
3

Scrap the wire

Reduce tension, adjustmt
Reduce temp

3
3
3

120
90
90

Issue MDF
Reduce tension, adjustmt
Reduce temp

10
10
10

4
3
3

3
3
3

120
90
90

10

Sensor malfunction

Check according to PM

120

Freq PM

10

90

Sensor not working

Defect wire ship
to customer

RPN Before Action

1108

RPN After Action

732

34

Appendix 3
Questionaire For QCC Curly Refresher Training
1)

Berapakah panjang wire yang patut dilebihkan selepas process Annealing?

A) 30mm
B) 300mm
C) 3000mm

2)

Wire selepas Annealing perlu dilebihkan untuk mengelakkan punca wire daripada
hilang dan termasuk ke lapisan bawah.
A) Betul
B) Salah

3)

Wire perlu diletakkan tape selepas job end di seksyen Annealing.

A) Betul
B) Salah

4)

Tujuan wire tidak boleh diletakkan tape selepas job end Annealing adalah untuk
mengelakkan operator memotong wire tanpa menanggalkan tape wire terlebih
dahulu yang akan mengakibatkan berlakunya spring back effect dan
entanglement.
A) Betul
B) Salah

5)

Spool hendaklah dipegang secara menegak semasa mengeluarkan wire untuk

product test.
A) Betul
B) Salah

6)

Lakarkan bentuk wire NG semasa curl checking di Rewinding sebelum

melakukan proses Rewinding.

35

7)

Berikan susunan langkah yang patut diambil sekiranya anda terjumpa vibration
yang kuat pada tansion arm di m/c Rewinding semasa proses sedang dijalankan.
I)
Hold & Stamp
II)
100% curl check
III)
Inform Leader or Supervisor
IV)
Stop the machine
V)
Inform QCC Curly Team or Engineering
A) I, II, III, IV, V
B) IV, I, III, II, V
C) II, III, IV, I, V

8)

Wire yang perlu diperiksa di QCIP tidak patut digulung semula secara
backward.
A) Betul
B) Salah

9)

Lakarkan ketiga-tiga jenis curly wire.

Type A
Type B

10)

Type C

Di bawah adalah perbezaan antara curly wire bagi Type B dan Type C, kecuali :
A) Wire Type B tidak ada kink tetapi wire Type C ada kink.
B) Jarak gelombang curl bagi wire Type B adalah sekata tetapi Type C tidak
sekata.
C) Kalau terjumpa Type B pada satu spool, seluruh lot wire perlu direject tetapi
tak perlu reject seluruh lot wire kalau terjumpa satu spool Type C.

36

Appendix 4
1.0

BACKGROUND

Recently, we are facing curly wire problem which is expectedly occurred at Rewinding
Section and this case should be seriously being taken so that excellent quality is
maintained and upgraded from time to time. Despite that we are having good QA team,
however, Production Section is the most worried of this curly wire because we are very
emphasizing quality as our main target besides volume and other achievements.
For that matter, Production is proposing to hire more staff for Rewinding Section so that
smooth running of the production line together with Quality Awareness could be
enhanced and maintained.
Figure 1 in Appendix shows Gun Chart for the Curly Wire Countermeasure.

2.0

PURPOSE

This proposal is mainly to practice curly wire checking of product wire at Rewinding
Section so that it could be detected at early phase. In addition, it is also to achieve fullyutilization of Rewinding m/c as a whole.

3.0

METHODOLOGY

3.1

Operators' Job Description

Curly wire checking at Rewinding would involve operators whom run the machine. As for
now, rewinding has 17 machines which comprises of 3 lines for each m/c and these lines
are labeled as Line A, Line B and Line C. As of our current practice, we have 13
operators as a whole and division for each shift is as follows:

1st Shift - 5 operators

(07:00 - 13:15)

2nd Shift - 4 operators

(13:00 - 23:15)

3rd Shift - 4 operators

(23:00 - 07:00)

Operators' job division at Rewinding is as follows:

Run m/c - 4 operators for 1st and 2nd Shift.

37

Job End - 1 operator for each shift

Job Start, Moving and Weighing Spool & Case - by themselves

Job division for each shift is as follows:

1st Shift -

4 operators run 14 m/c ( 3 or 4 m/c each)

1 operator (SO) job end
OT (if any) spool & case weighing, or else it is done by
the operator run the m/c itself. OT operator also has to
run m/c 15,16 & 17 (at the back), otherwise, it stop.

2nd Shift -

As above, OT is encouraged from 1st Shift.

3rd Shift -

3 operators run the m/c

1 operator job end.
M/c 15,16,17 has to stop due to manpower shortage.

Operators who run the m/c have to undergo curly wire checking, therefore, we have to
minimize the number of m/c they are operating. We are proposing each operators to run
3 m/c. So, for this proposal, Rewinding requires: 6 operators for each shift.
Thus, the proposed job division for each shift is (Operators' location layout is shown
in Appendix Figure 2) :

4 operators run m/c and curly wire checking, namely

1 operator - m/c 1,2,3

1 operator - m/c 4,5,6
1 operator - m/c 7,8,9
1 operator - m/c 10,11,12
1 operator - m/c 13,14

1 operator (SO)

Job start and job end

Since moving and weighing spool & case is one of crucial job,
and Rewinding has manpower shortage, this job is proposed to be
accomplished by OT person.

Two methods are proposed which are shown in Diagram 1 and Diagram 2. Method 1
needs Process Engineering to change the set condition so that wire lead would be 20 for
curl check.

38

Diagram 1 below shows the flow chart Method 1 for Running Wire at Rewinding:

OPERATOR RUN
WIRE

WIRE
STOP

CUT EXTRA 250mm AND PUT

THE WIRE ON THE JIG

RUN NEW
WIRE

CHECK
WIRE'SCURL

NOT
OK

OK

END TAPE THE

WIRE AND CUT

JOB
END

INFORM
LEADER
QAO TO
CONFIRM
SCRAP IF
REJECT
PROCEED IF
ACCEPTED

39

Diagram 2 below shows the flow chart Method 2 for Running Wire at Rewinding:

OPERATOR RUN
WIRE

WIRE STOP. END TAPE

AND CUT WIRE WITH
EXTRA ABOUT 250 mm

PUT THE WIRE ON

THE JIG

RUN NEW
WIRE

CHECK
WIRE'SCURL

NOT
OK

OK

CUT THE EXTRA

WIRE

JOB
END

INFORM
LEADER
QAO TO
CONFIRM
SCRAP IF
REJECT
PROCEED IF
ACCEPTED

40

3.1

Jig Fabrication

Each m/c is provided with one jig. The function of this jig is for the operator to put the
product spool on it before undergo curly checking. The rough sketch of this jig is shown
in Figure 3 in Appendix A. Production would discuss with Engineering in fabricating of
this jig which material suitable is from PVC-Transparent. This jig could accommodate 3
product spool.
Basically, the operator would run the m/c as usual. When the m/c stop, the operator had
to put aside the completed product wire on the jig located nearby. As discussed earlier,
there are 2 methods which being shown in flow chart.
The jig has come into two sizes; one for AL4-spool and another one is for AL2_spool as
shown in the Appendix A. In total, the jig required by Rewinding is 15 for AL4-spool and
10 for AL2-spool.

4.0

RESULT AND DISCUSSION

Operators who run the m/c have to undergo curly wire checking, therefore, we have to
minimize the number of m/c they are operating, so that:
Thorough inspection could be done. With this, operators are more concentrated to
check the wire curl. If only one operator does curly wire checking, we have to provide
one station for the checking. The completed products are sent to this station before
checking.
1) This may need more space.
2) Double-work. The operator has to remove the wire from the case to do the
checking. This may lead to mishandling.
3) We may encounter accumulated wire at checking station due to manpower
shortage. Thus, job end volume would decrease.
Maximize m/c utility. With minimizing the number of m/c for operator, m/c utilization
could be increased.
Increase volume achievement. Thus, when the m/c utilization increases, and more
manpower, volume achievement would be more efficient and excellent.
Mishandling could be avoided. As we discussed earlier, mishandling would be
eliminated.
Jig is designed so that it would be efficient as product's placement. It is made from PVC
which is suitable in a clean air environment. It has no hazardous effect or harmful to the
operator. The jig is of low material cost and simple machining is done in-house.
Method 2 is advisable as compared to Method 1 because the latter may cause loose
wire. However, both methods need careful handling.

41

5.0

RECOMMENDATION AND FUTURE WORK

The progress would be monitored monthly and compared them between before and after
accomplishment of this method. Targeted period for full-observation is about 6 months.
Of course, from time to time, the procedure would be updated for betterment of both
Quality and Quantity of our products.

C:\Documents and
Settings\chwong\Desktop\Curly study\QCC Curly study 1999\Module training.ppt

Appendix 5

C:\Documents and
C:\Documents and
Settings\chwong\Desktop\Curly
Settings\chwong\Desktop\Curly
study\QCC Curly studystudy\QCC
1999\CurlyCurly
wire study
QCC team
1999\QCC
Improvement
Curly Wire
andProposal
corrective
2000.ppt
action.ppt

42

Appendix 6
MALAYSIAN ELECTRONICS MATERIALS SDN. BHD.

QCC AUDIT DISCREPANCY REPORT

SECTION FOUND :
TYPE

: Curly

ISSUE DATE

ISSUE PERSON

TO SECTION

DISCREPANCY :

__________________________________________________________________________________
_________
____________________________________________________________________________________
_______
________________________________________________________________________________________________________
________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________
_________________________________________________________________________________________________________________________

Replied by:

________________________________

Date

Approved by:

________________________

Date

Approved by:

________________________
Date

QCC Team Chairman

43

Appendix 7

C:\Documents and
Settings\chwong\Desktop\QCC Qurly team\hook simulation test (Curly defeat)\Study effectiveness procedure.ppt

Appendix 8
Soalan:
1) Semasa RWD process setiap spool manakah mesti buat curl check?
a. Mother lot spool setiap set up process

b. Setiap roduct spools

2) Apakah tindakan yang perlu anda lakukan sekiranya wire break berlaku ketika
RWD machine tengah beroperasi?

3) Mengapa anda perlukan untuk tidak melepaskan wire secara mengejut selepas
End Tape?

4) Mengapakah setiap End Wire pada ANL mother lot perlu diikat pada hook?

5) Apakah itu curly dan lukiskan jenis curly yang anda tahu?

6) Apakah yang perlu anda lakukan ketika process remains wire?

7) Sila tuliskan kebarangkalian wire curly boleh terjadi di process anda?

8) Kesan kesan terhadap MEM sekiranya wire yang kita hantar ke customer
mempunyai defect wire curly

44

Appendix 9

C:\Documents and
Settings\chwong\Desktop\QCC Qurly team\SOP & WI vursus current practise.pdf

Appendix 10
Machine

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42

End tension last layer

Line A
Line B
Line C
4.1
3.9
3.4
3.6
2.5
1.2
2.3
3.4
3.5
3.7
3.6
3.3
3.6
3.6
3.6
3
3.3
3.4
3.5
3.3
3.4
4.3
4.2
3.8
4.2
3.3
3.7
3.7
3.6
3.3
4.1
4.4
2.2
4.7
3.1
3
3.6
1.7
3.7
3.3
3.8
3.8
3.3
2.3
1.9
2.9
3
3.7
3.9
2.9
3.6
3.5
3.6
3.4
3.3
3.6
2.2
3.5
3.6
3.7
4.7
4.6
2.2
4.2
4.2
2.6
4
4.3
2.2
4.1
4.2
3.5
4.2
4
2.2
4.3
4.5
2.2
4.3
4
2.2
4.2
4
2.2
4.4
4.4
3.6
3.7
4.3
2.2
4.6
4.4
2.2
4.2
4.2
2.2
4.7
4.7
2.2
4.3
4.3
4.1
4.3
4.3
2.2
4.7
5
2.2
4.5
4.3
2.2
4.1
4.4
2.2
4
3.8
2.2
4.5
5.3
2.2

Setting Condition
winding cond ; 158
Tension setting : 2.2
set count : 630
item : RN30243JFL

Parameter
End tension last layer gauge
End stop tension machine
Line A
Line B
Line C
Line A
Line B
Line C
4.6
4.5
3.4
3.8
3.6
3.3
3.5
2.5
1.5
3.4
2.3
1.1
3.5
3.5
3.6
3
3.1
3.3
3.7
3.6
3.5
3.6
3.4
3.1
3.7
3.7
3.6
3.1
3.4
3.3
3
3.5
3.8
2.8
2.9
3.2
3.3
3.7
3.6
3.2
3.1
3.2
4.5
4.2
3.9
4.2
4
3.5
4.3
3.5
4
4
3
3.4
3.9
4.2
4.1
3.5
3.3
3
4.5
4.4
2.5
3.9
4.2
2
5
3.4
3.5
4.5
2.9
2.8
3.6
2
4
3.3
1.4
3.5
3.3
3.7
3.7
3
3.6
3.6
3.3
2.6
1.8
3.2
2.2
1.7
2.7
3
3.9
2.7
2.8
3.5
3.9
2.8
3.8
3.7
2.7
3.4
3.4
3.5
3.1
3.3
3.4
3.2
3.4
3.7
2.2
3.1
3.5
2
3.5
3.7
4
3.3
3.4
3.5
5
4.6
2.2
4.4
4.4
2
4.5
4.2
2.5
4
4
2
3.7
3.8
2.2
3.8
4.1
2
4
4
3.2
3.9
4
2
4.3
3.8
2.3
4
3.8
1.9
4.5
4.7
2.3
4.1
4.3
2
4.5
4.4
2.6
4.1
3.8
2
4.7
4.4
2.6
4
3.9
2
4.9
4.6
3.5
4
4
1.6
4
4.1
2.9
3.5
4.1
2
5
5
2.7
4.2
4
1.9
4.3
4.2
2.3
3.9
3.9
2
4.7
4.7
2.7
4.2
4.2
1.9
4.5
3.8
4.2
4.1
4.1
2.2
4.3
4.2
2.4
3.9
3.9
2
4.5
4.8
2.4
4.5
4.8
2
4.8
4.5
4
4.3
4.1
2.1
4.1
4.1
2.3
3.9
4.2
2
4.5
3.5
4.4
3.8
3.6
2.1
4.5
5
2.9
4.3
5
2

End stop tension gauge

Line A
Line B
Line C
4.3
3.9
3.4
3.5
2.6
1.7
3.5
3.5
3.7
3.8
3.6
3.5
3.5
3.9
3.5
3
3
3.5
3
3.5
3.4
4.6
4.2
3.8
4.5
3.5
3.5
4.4
4
4
4.6
4.6
2.5
4.6
3.4
3.6
3.4
1.9
3.8
3.3
4.1
4
3.4
2.7
1.9
2.9
3.1
3.8
4
2.8
3.7
3.5
3.7
3.2
3.2
4.1
2.2
3.7
3.8
4.2
5
4.8
2.3
4.7
4.7
2.4
3.9
4.3
2.2
4.7
4.7
2.1
4.5
4.5
2.3
4.7
5
2.4
4.7
4.6
2.7
4.9
4.7
2.7
4.7
4.6
2
4.1
4.5
2.8
4.8
4.9
2.6
4.6
4.3
2.2
4.4
4.9
2.2
4.7
4.2
2.5
4.3
4.3
2
5
5
2.5
5
4.5
4
4.4
4.5
2.3
4.4
4.2
2.3
4.7
5
2.7

Red font means more than 5 value

Appendix 11

C:\Documents and
Settings\chwong\Desktop\QCC Qurly team\training material for operator.ppt

45