PROBLEM SOLVING

IN

MANUFACTURING
KEY PERFORMANCE INDICATOR in MANUFACTURING :

1. SAFETY
2. QUALITY
3. DELIVERY
4. EFFICIENCY

1. SAFETY
 Safety of product to send to Customer
 Safety in Manufacturing process (safety for the employees)

2. QUALITY
 Customer Satisfaction (Measured using PRR (Product Return Rate)
 First Pass Yield, MDR (Manufacturing Defect Rate), DPMO (Defect Part per
million opportunities) and others
 Good product deliver to Customer

3. DELIVERY
 On time delivery to Customer

4. EFFICIENCY
 Productivity (KE, NEE/OEE), Electricity and many others
 Eliminate Waste
SAMPLE PROBLEM IN MANUFACTURING :

1. In Safety :
- Accident occurred during production / manufacturing process.
- Product burn and explode and impact to customer injury.

2. In Quality :
- Defect product leakage to customer (Functional Not Good)
- High defect rate in manufacturing process.
- Cost Non Quality

3. In Delivery
- Late delivery to customer.

4. Efficiency
- Low productivity, a lot of Waste , etc.

SO … ALL THIS PROBLEM HAVE TO SOLVE

AND COMING FROM THIS OCCUR :
“PROBLEM SOLVING TOOLS / METHOD”
PROBLEM SOLVING TOOLS / METHOD THAT COMMONLY USE
IN MANUFACTURING :

1. DATA COLLECTION AND ORGANIZATION TOOLS

1.a. FISH BONE DIAGRAM / CAUSE EFFECT DIAGRAM :

Measurement Material Method

EFFECT

Environment Man Power Machine

CAUSE
1.b. BRAIN STORMING :

USING TO GENERATE A STORM OF IDEA OR THOUGHTS / THINKS….

2. DATA DISPLAY / ANALYSIS TOOLS :

2.a. PARETO CHART

Pareto Chart of Process

30 100
25
80
Time (minute)

20

Percent
60
15
40
10
5 20

0 0
Process

Time (minute) 15.5 4.5 4.0 2.0 2.0 1.0

Percent 53.4 15.5 13.8 6.9 6.9 3.4
Cum % 53.4 69.0 82.8 89.7 96.6 100.0
2.b. PIE CHART

RCV defect detail by problem cause

Wrong
Missing Orientation
Comp. 2%
15%

Short Solder
25% No Solder
58%

2.C. TREND CHART

NEE - OEE Trend SMT 1 - FUJI PCBA Sensor 2012

50.00%

40.00%
Percentage

30.00%
NEE
OEE
20.00%

10.00%

0.00%
Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
NEE 22.49% 26.98% 28.46% 37.14% 36.25% 32.59% 37.99% 38.93% 35.55% 40.10% 42.51%
OEE 24.54% 29.02% 30.17% 40.46% 40.06% 36.94% 39.94% 41.57% 40.89% 43.91% 46.46%

Month
COMPREHENSIVE PROBLEM SOLVING TOOLS / METHOD THAT COMMONLY USE
IN MANUFACTURING :

1. SIX SIGMA (DMAIC Methodology)

Using data collection and Organization Tools also analysis tools
such “Fish Bone” diagram , Pareto and others

2. KAIZEN (DMAIC Methodology)

Eliminate waste such as :
- Transportation
- Inventory
- Motion
- Waiting
- Over production
- Over processing
- Defect / Rework

3. 8D METHODOLOGY
- D1 : Define the team D5 : Define the problem correction
- D2 : Describe the Problem D6 : Implement and check problem correction
- D3 : Contain the problemD7 : Prevent the problem
- D4 : Identify the root cause D8 : Close the problem
DMAIC METHODOLOGY :

1. DEFINE

2. MEASURE

3. ANALYZE

4. IMPROVE

5. CONTROL

SOME TIMES PROBLEMS THAT OCCURRED IN MANUFACTURING CAN BE

SOLVED ONLY BY IMPLEMENTING 5S :

1. SORTING (SEIRI)
2. STRAIGHTENING / SETTING IN ORDER TO FLOW (SEITON)
3. SHINE (SEISO)
4. STANDARDIZE (SEIKETSU)
5. SUSTAIN (SHITSUKE)
 5S SAMPLE :

Stencil arranged following order Simple database for searching stencil ICT fixture arranged in rack
in rack stencil with addressing

Component arranged in bin with detail Loading list document arranged tidy in Document arranged follow order
Identification and location. Rack cabinet.