qcc-curly final

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QCC Curly team

Closing report

Prepare By: CH Wong and Norasmadi

1

Content1.0 Introduction................................................................................................. 31.1 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

2

1.0 Introduction1.1 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

Cause Wire entwine at tension arm Wire entangle at tension weight Wire caught at cable tier head Wire mis-setting and hang at tension arm pulley shaft Wire hang at small radius object like cable tier, counter cover, tension weight, etc. Wire out of pulley during rewinding process Loose wire at annealed product Improper handling of annealed product

Action Fix high friction rubber at tension arm Installation of tension box cover Grind protruded pulley shaft Installation of tension arm pulley sensor on Rewinding mc

Methodology Semi MistakeProofing Semi MistakeProofing Semi MistakeProofing MistakeProofing MistakeProofing Training

B C

Installation of tension arm pulley sensor at Rewinding Annealing operators are urged to handle annealed product spool horizontally. 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

3

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.

4

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 Curly4 3Cases

Before Improvement

After Improvement

2 1 0Apr 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

5

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 Total

9 8 1 0 0 1 1 0 0 0 0 0 0 1 0 21

8 4 2 0 0 1 0 0 0 0 1 0 1 0 0 17

2 0 1 0 1 0 0 0 0 0 0 0 0 0 0 4

1 0 0 0 0 0 0 1 1 0 0 0 0 0 0 3

0 2 0 2 1 0 0 0 0 0 0 1 0 0 0 6

0 1 0 1 0 0 0 0 0 1 0 0 0 0 0 3

0 3 2 1 0 0 0 0 0 0 0 0 0 0 2 8

Table 2: Defect customer complaint from 2003 to 2009

Customer Claim by Year vs Defects CategoryF o re ign M a te ria l B a ll s ize pro ble m

24 21 18 15 12 9 6 3 0 2003 2004 2005 2006 2007 2008 2009 Ye ar

EF O Ope ne d S pl c a s e dirty Wire lo o p de fo rm pro ble m Wro ng c a rto n bo x la be l c o lo r Wro ng la be l Wro ng s pl c o lo r 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 S tic ky

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.

6

No

RMA