Leader: H The Mentor: L Thiru

Team Member: T.Ngoc/Tan/Phuong Supervisor T Bot

Engineering Report : Wave Machine Improvement Vi/N.Ngoc/Long

A. OPPORTUNITY: Reduce Wave Machine Downtime E & F. DEVELOP & IMPLEMENT COUNTERMEASURES: DO
Plant: VNS1-01-02 Investment Costs ($):$129,022 Date: 3/21/2023 Root Cause Selected Countermeasure Owner Target Finish
Group: Wave Annual Savings ($): Define standard guidline for designing pallet The 10/10/2022 11/6/2022
Optimize PM Job and define specific hour PM
B. CLARIFY THE PROBLEM: PLAN Tan/Phuong 3/15/2023 3/22/2023
1) No Standard (day/week/month) for machine/pallet
- 66% (102 hrs) downtime on Wave Soldering machine from Nov Y'22 to midle of Mar Y'23 Key metric to impact: guideline for Weekly send schedule PM to PMC/Production Ngoc 3/22/2023 / /
- High potential for PCBA scrapped Downtime & Quality designing Pallet Create standard process In/Out at washing pallet Tan/Phuong 3/25/2023 / /
Fixture. Work with Vendor to modify old pallet with Side Rail 4/20/2023
Wave Soldering Dowtime The/Ngoc / /
Problem Identification 2) No Standard Work with Vendor if can upgrade software (stop conveyor) The/Ngoc 4/20/2023 / /
Who: Operations-WAVE preventive
Design tool to support repair finger The/Tan 3/30/2023 / /
maintenance pallet
What: Machine Downtime & PCBA 3) Only PM by Work Load Analysis The 3/25/2023 / /
Scrapped Daily & weekly, Temporaty repair all finger Wave#2 Wave Team 3/18/2023 3/20/2023
monthly not Release CER to get spare part The/Bot 3/21/2023 / /
Where: Wave#2, Wave#3
activated yet / / / /
When: Pallet drop / / / /
/ / / /
C. BREAKDOWN THE PROBLEM: PLAN G. EVALUATE RESULTS: CHECK
Describe the Process: Waste(s) Identified How does the result compare to target? How well did the countermeasure (s) work?
- Top Issue are related to soldering defects. Work in progress to improve the quality issue. Transportation
- Pallet Drop 12 hrs of downtime concentrated on Wave#2, and 21 hrs on Wave3. Inventory
- 31% Pallet drop is critical on the process.
Motion
- Actual total PM (Daily 25%, weekly 66%)
Waiting X
Ovreproduction
Overprocessing
Defects X
Skills Unused

D. SET A TARGET (The challenge): PLAN

Improve: 1. Reduce machine DT due to pallet drop to below 3%
2. Perform monthly & weekly PM as per schedule
Current: 28%
Target: 3%
When: May 2023.

E. ANALYZE THE ROOT CAUSE: PLAN

- The root cause with areas highlighted in red is shown below:

Finger is bent, worn out lead to Pallet Drop

Machine Method
- Preventive Maintenance
- Pallet dimension worn out Not follow Schedule
Narrow the width of the conveyor Only partially responsive according to user manual
- Pallet Jam on conveyor - Repair spare part by manual (Finger, spring Clip)
- Bottom of pallet jam at solder pot Not special tool to repair
Pallet design for high components - Old & New Product Mix (01wave/03product together)
Lack of standardization guideline for designing Pallet Fixture Origin design of width (234mm), old pallet worn out (230mm)
- Machine setting Side rail of old pallet can not replace
Lead clearance between Pallet & Solder pot lack of standardization - Pallet Design
Technician does not check sequentially according to parameter setting Lack of standardization guideline for designing Pallet Fixture
- The screw at the bottom of the pallet is loose - Machine health check
Preventive maintenance Not deploying machine health checks every year
Lack of standardization PM Pallet
Not checksheet record Manpower
- The Top Catcher's latch has come off - Not standardization preventive maintenance plan
Preventive maintenance - There are not enough people doing PM follow plan H. STANDARDIZE: ACT
Lack of standardization PM Pallet
Not checksheet record - Not sequentially according to parameter setting
- Solder dross stuck on Solder pot Individual skill factors Means of Standardization:
Maintenance not follow schedule Organizational factors
- Software of machine Standard Work [ X ] Visual Aids [ X ] Procedures [ ] Training [ X ] Other [ ]
Overload motor converyor, alarm but not stop conveyor Material
Alarm of conveyor (Ignore, Warning) Software access limited to stop conveyor - Finger is consumable material Process Audits:
- Finger stuck at the Guidline bar on main bar Consumable materials usually consume very quickly when used after a
Maintainability limited (finger) period of time you need to replace and repair them constantly.
TPM Checklist [ ] 5S Audit [ ] Other [ ] _____________________________
- Automatic chain lubrication Lack of schedule periodic backups
Not equipment for automatic apply oil for chain - Quality of pallet Next challenge:
- Size of finger L & V Side Rail by Durostone, not Titan
Currently the pallet is with Side Rail a block, so over time, the pallet is worn, the Finger Environement Further changes to sustain improvement
"V" mechanism does not hold the pallet well - High temperature at solder pot
- The finger is not regularly calibrated and maintained
Lack of preventive maintenance plan for finger

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