1. .

?

R&D

Mass Production Mass Customization

1
1. .

A B

A Patten

B Patten

1970 1980 1990 2000

JUST IN TIME

2
1. ? . & Q.C.D.

Digital, Knowledge, Fusion

3C (Customer, Competition, Change)
, No 1, Only 1

3
2. ? . & Q.C.D.

? ? ?

PRODUCT PROCESS PEOPLE

4
2. ? . & Q.C.D.

:
:

: / :

5
3. () ? . & Q.C.D.

[] Innocent (, , )
; Zero Base

, 30

6
3. () ? . & Q.C.D.

!
()

.

( )

7
4. . & Q.C.D.

8
4. . & Q.C.D.

1 : . ( .)

2 : .

( .)

3 :

9
4. . & Q.C.D.

%
25

20
5~10%
4
15 ()
5 10~15%
10 (GE)
/
6
5 Motorola

PPM 3.4 233 6,210 66,807 308,537 500,000

Sigma 6 5 4 3 2 1

10
 4. . & Q.C.D.

4 4
5
6

0 0 0

11
1. .

(Material: ) (Man),

(Machine) Service( )

(Process).

Input Output

(Man)

(Machine)
(Material) Service
,

: Man (), Machine (), Material (), Energy + Information()

12
1. .

In put Out put ,
.

Out put
=
Input

< >

Out put ,
1 Cost down
In put In put
Out put In put ,
2
In put Out put
Out put (,)
3
In put In put ( )

13
1. .

=



=




=

: ,

: (, )

14
2. .

Q C D M S

[Quality, Cost, Delivery, Manpower, and Safety]

15
2. .

.!!!

,(Jig & Fixture ),

-
- 3

16
2. .

/ /
/

/ / /

17
2. .

18
2. .

[60%]

. . .
. . .
. . .

// [30%]

, , , ...

[10%]
.
.
.

, !!!

19
2. .

( )

20
2. .

3
(Mind) :
() .

(Product) : , /
.

(Process) : , /
.

Business Management

Product Process Structure

Service
Innovation
()

Mind

Restructuring Behavior Reengineering

Culture

21
1. Q-Cost . Q.C.D.

Q-Cost

: ,

: 1953
(ASQC) 7 W.H.LESSER (Quality
Cost) , 3
.

$

(Prevention
Quality-Cost (Failure Cost) (Appraisal Cost)
Cost)

22
1. Q-Cost . Q.C.D.

Reject (Scrap)
Drop /

Reject (Scrap)
/ Rework
COPQ

/
CS Claim

Loss

23
2. COPQ . Q.C.D.

COPQ
Process , ,


(), (),

- , , , , , , ,

COPQ
COPQ
6 10%
5 10 - 15%
4 15 - 20%
-----------------------------
3 20 - 30%
2 30 - 40% 6 PJT : 3.9

24
2. COPQ . Q.C.D.

( )
( )

5-8%

15-20%



( )
/

(Hidden Factory)
25
1. .

(/MH)
(/MH)
PQCDMS-UP Balance (:*/H)
(/)

(Productivity)

(, ppm)


(Quality) (Safety)
, RTY


(, )

()
(Morale) (Cost)


Line

(Delivery)

26
26/55
2. .

, .
=

(, , , TOOL )
.
- :
- : : , ,

- :

. , ,
.

MTBF
M.T.B.F
(Mean Time Between Failure : )

1
M.T.T.R (Mean Time To Repair : )

27
2. .

, .

Operator ,

, ,

,

,

( , ) ()

( , )

28
2. .

(480-)
(, , )

(, , )
+
( )

( )

% ( ) 100
% ( ) 100
% ( ) 100

% ( + ) 100

29
4. .

HP = F(HA x M)
2

Human Performance :
Human Ability :
Morale : (//)

30
30/55
4. .

: ()
(OUTPUT)
= =
(INPUT)

,
, ,
.

31
5. .

LOSS (Output)
INPUT

Cost
Down
Down

Down

32
5. .

MTBF ( )

A 1 A 2 A 3
A N

M TBF = A1 + A2 +A3 + +AN

N
= - ( D /T + D /T )

) 7 2 0 1 0 0
+ D /T 2 0
M T B F = 7 2 0 - 2 0
100
7 .

] Mean Time Between Failure

33
5. .

MTTR ( )

B1 B2 B3 BN

M TTR = B1 + B2 + B3 + + BN
N
=

) 1 0 0 0 5 0
M T T R = 100 0
= 2 0 /
50
2 0 .

] Mean Time To Repair

34
6. .

, ,

35
6. .

(Yield)

, .

(Yield)
(FTY, First Time Yield) :
. /
.
(RTY, Rolled Throughput Yield) :
.
.
(YNOR, Normalized Yield) :
,
.

36
6. .

95.5%

45,000 ppm
97%

94.4%
30,000 ppm

RTY = 0.955*0.97*0.944 = 87.4% 56,000 ppm

RTY

37
7. Point .

?

/

, , , ,

.

.



= +

38
7. Point .

.

.

.()










[] [] ()
KNOW-HOW
()
SW on/off
[] () [] ()
(TIP) Loading
Un Loading
39
7. Point .

()
[ ]
-Line unbalance
Spec Rule() Handling
Rule
- 5S(3) [ ]

OO()
!... -
.

...

40
7. Point .

7
()
.

, ,
?
41
7. Point .

3
1 :
2 :
3 : .

.
,
.
.

42
7. Point .

5-Why

(Why)
.

3 5-Why

STEP-1 3
1 : ,
2 : () ,
3 : .

STEP-2 (Why)
.

STEP-3 ?(How)
IDEA .

STEP-4 (Improve)

, , , .

43
7. Point .

1. 3 5S 2.

.

Data

(Line Stop)
Loss


Loss
, ,

Loss Loss

,
,
Timing

4. 3.

44
The Guide for
Innovation
Leaders

45
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