qcc-curly final

1

QCC –Curly team

Closing report

Prepare By: CH Wong and Norasmadi

2

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

3

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 Cause Action Methodology

A

· 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.

·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

·Semi Mistake-

Proofing

·Semi Mistake-

Proofing

·Semi Mistake-

Proofing

·Mistake-

Proofing

B

· Wire out of pulley during

rewinding process

· Installation of tension arm

pulley sensor at Rewinding

·Mistake-

Proofing

C

· Loose wire at annealed product

· Improper handling of annealed

product

· Lost of wire source due to spring

back effect at annealed product

· Sticky wire

· Annealing operators are urged to

handle annealed product spool

horizontally.

· Annealed product shall not be

rewound in backward direction of

winding rotation.

· Real time checking before

rewinding

·Training

·Training

·Training

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

4

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.

5

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

0

1

2

3

4

Apr May June Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May June Jul Aug Sep Oct Nov Dec

Month

Ca

se

s

After ImprovementBefore Improvement

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 , that’s

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

6

Table 2: Defect customer complaint from 2003 to 2009

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.

Defect 2003 2004 2005 2006 2007 2008 2009

Sticky 9 8 2 1 0 0 0

Curly 8 4 0 0 2 1 3

Loose 1 2 1 0 0 0 2

Spool Glue 0 0 0 0 2 1 1

Wrong tape colour 0 0 1 0 1 0 0

Entanglement 1 1 0 0 0 0 0

Wrong wire type label 1 0 0 0 0 0 0

Wrong spl color 0 0 0 1 0 0 0

Wrong label 0 0 0 1 0 0 0

Wrong carton box label color 0 0 0 0 0 1 0

Wire loop deform problem 0 1 0 0 0 0 0

Spl case dirty 0 0 0 0 1 0 0

EFO Opened 0 1 0 0 0 0 0

Ball size problem 1 0 0 0 0 0 0

Foreign Material 0 0 0 0 0 0 2

Total 21 17 4 3 6 3 8

Defect 2003 2004 2005 2006 2007 2008 2009

Sticky 9 8 2 1 0 0 0

Curly 8 4 0 0 2 1 3

Loose 1 2 1 0 0 0 2

Spool Glue 0 0 0 0 2 1 1

Wrong tape colour 0 0 1 0 1 0 0

Entanglement 1 1 0 0 0 0 0

Wrong wire type label 1 0 0 0 0 0 0

Wrong spl color 0 0 0 1 0 0 0

Wrong label 0 0 0 1 0 0 0

Wrong carton box label color 0 0 0 0 0 1 0

Wire loop deform problem 0 1 0 0 0 0 0

Spl case dirty 0 0 0 0 1 0 0

EFO Opened 0 1 0 0 0 0 0

Ball size problem 1 0 0 0 0 0 0

Foreign Material 0 0 0 0 0 0 2

Total 21 17 4 3 6 3 8

0

3

6

9

12

15

18

21

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2003 2004 2005 2006 2007 2008 2009

Year

Customer Claim by Year vs Defects CategoryFo reign Materia l

Ball s ize pro blem

EFO Opened

Spl cas e dirty

Wire lo o p de fo rm pro blem

Wro ng ca rto n bo x labe l co lo r

Wro ng label

Wro ng s pl co lo r

Wro ng wire type labe l

Entanglement

Wro ng tape co lo r

Spo o l Glue

Lo o s e

Curly

S ticky

7

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

No RMA Description

1 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.

2 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.

3 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

8

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

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

Advisor

SC Puah

LeaderCH Wong

QANorita

SecretarySalmiah

ProductionSuzila

Process Engineering

Faridah

Production Azri

Advisor

SC Puah

LeaderCH Wong

QANorita

SecretarySalmiah

ProductionSuzila

Process Engineering

Faridah

Production Azri

9

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.

10

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

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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.

12

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

13

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.

14

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 QCC-

Curly 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

15

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:

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.

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

16

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.

17

3.0 Activity and Implementation

3.1 Gantt chart for QCC curly team

Figure 8: Gantt chart for QCC curly activities

18

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.

20

1

Betul semua

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

100%

21

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.

22

(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

0

1

2

3

4

5

6

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

Machine

Te

ns

ion

(g

)

Line A

Line B

Line C

Graph 4: End Tension Last Layer-Machine Indication

End Tension Last Layer-Gauge Indication

0

1

2

3

4

5

6

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

Machine

Te

ns

ion

(g

)

Line A

Line B

Line C

Graph 5: End Tension Last Layer- Machine Indication

Stop Tension - Machine Indication

0

1

2

3

4

5

6

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

Machine

Te

ns

ion

(g

)

Line A

Line B

Line C

Graph 6: Stop Tension –Machine indication

23

Stop Tension - Gauge Indication

0

1

2

3

4

5

6

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

Machine

Te

ns

ion

(g

)

Line A

Line B

Line C

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 Machine Quantity

Initial tension >= 3.5g

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.

24

Remarks

April

Type Machine item tension set max ten capability wk4 wk1 wk2 wk3 wk4

PC98 1 >=3.5g 7g completed


PC98 3 <=1.8g 3.5g completed

PC98 4 <=1.8g 3.5g completed

PC98 5 1.9 ~ 3.4g 5g completed


PC98 7 1.9 ~ 3.4g 5g




PCAT 11 1.9 ~ 3.4g 5g completed












PCAT 25 <=1.8g 3.5g completed




PCAT 29 >=3.5g 7g completed














Plan

Completed

Modification schedule

May

Table 5: Schedule Rewinding Machine Calibration and Tension Board Adjustment

25

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

26

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

27

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

28

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,

29

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

0

1

2

3

4

5

Jan-

09

Feb-

09

Mar-

09

Apr-

09

May-

09

Jun-

09

Jul-

09

Aug-

09

Sep-

09

Oct-

09

Nov-

09

Dec-

09

Jan-

10

Feb-

10

Mar-

10

Apr-

10

May-

10

Jun-

10

Jul-

10

Aug-

10

Sep-

10

Oct-

10

# S

PA

# curly

After set up

activities

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

Graph 20: Curly defect before & after set up activities

30

Curly summ. by section

0

1

2

3

DWG ANL RWD QAO

# i

ss

ue S

PA

2009 2010

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

Curly summ. Before & after set up

0

1

2

3

4

5

# SPA

# S

PA

2009 2010

Graph 22: SPA (Curly) before and after setup

Curly sum issuance by spool status

0

1

2

3

4

5

2009 2010

# prd spool # ANL spool

Graph 23: SPA (Curly) issuance by spool status

31

Curly sum by status

0

1

2

3

4

5

2009 2010

Waive Reject

Graph 24: SPA (Curly) waive and reject status

External CAR from customer

Customer Complaint

R907-008Panasonic

(S)

1) Wire curling up is seen on "NG"

wire lot. 2) Product using "NG" wire

shown curvy looping.

RF00275JPN 23/07/09

R911-003 Asat DG

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.

R4K0246JAG 10/11/09

R912-008 RIST

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.

RGS0485BR1 23/12/09

R1001-002 &ROHM

APOLO

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

RGS0485BR1 22-01-10

R1002-001ROHM

APOLO

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.

RGS0485BR1 01-02-10

Received

Complaint DateRMA -No Customer

Defects DescriptionItemcode

Table6: Customer complain 2009~2010

32

Yearly Curly complaint from Customer

0

1

2

3

4

5

Customer Complaint

2009

2010

Graph 25: Yearly complaint from customer 2009/2010

Montly total valid claim

0

1

2

Jan-

09

Feb-

09

Mar-

09

Apr-

09

May-

09

Jun-

09

Jul-

09

Aug-

09

Sep-

09

Oct-

09

Nov-

09

Dec-

09

Jan-

10

Feb-

10

Mar-

10

Apr-

10

May-

10

Jun-

10

Jul-

10

Aug-

10

Sep-

10

Oct-

10

Month

Cla

im Total

After set up activitiesBefore set up activities

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”

33

5.0 Appendix

Appendix 1

Type A Type B Type C

34

Appendix 2

Item : Cover at Tension Arm

Process Potential Potential Effect Sev Class Potential Causes Occ Current Process Control Det RPN Recommended Action

Function Failure of Failure Sev Occ Det RPN

Setting wire Mis-setting Hang at weight 8 Did not properly done 5 Re-set wire 4 160 Re-set wire 5 1 1 5

Hang at shaft 8 Due to c/bench air blow 4 Re-set wire 4 128 Re-set wire 4 3 2 24

Hang at pulley cap 8 Did not see 4 Re-set wire 6 192 Re-set wire 8 4 6 192

Hang at cable tier 8 Due to c/bench air blow 4 Re-set wire 3 96 Change direction & use thread 4 2 5 40

Hang at stopper 8 Did not properly done 2 Re-set wire 1 16 Re-set wire 5 1 1 5

Mishandling Touch wire with finger 4 Finger 7 QAO to decide 6 168 Consult QAO 4 7 6 168

Touch wire with tweezer 8 Do in fast pace 6 Scrap 3 144 Holding only spool or tweezer 8 6 3 144

Touch case when packing 7 Did not use proper 6 Scrap 3 126 Follow procedure 7 6 3 126

procedure

Drop 8 Rough handling 3 Scrap 1 24 Training 8 3 1 24

Loose Wire Tension variation 8 TBA 3 Adjustment 2 48 Adjustment 8 3 2 48

Spool holder loose 8 Did not place spool 5 Place properly 5 200 Check after place spool 8 5 5 200

correctly

Loose spring 2 Change spring/holder 6 96 Freq PM compare to previous 8 2 4 64

Traverse not smooth 9 High friction 1 Apply PM 7 63 Freq PM compare to previous 9 1 5 45

RPN Before Action 1461 RPN After Action 1085

Item : Tension Board Adjustment

Process Potential Potential Effect Sev Class Potential Causes Occ Current Control Det RPN Recommended Action

Function Failure of Failure Process Sev Occ Det RPN

Tension Board Tension Arm Loose wire 10 Tension vibrate hard 5 Redo TBA 4 200 Redo TBA 7 4 4 112

Adjustment Vibrate

Sticky wire 10 Tension too high 5 Reduce tension reading 5 250 Redo TBA 7 4 5 140

Curly wire 10 Vibrate too freq and hard 2 Redo TBA 4 80 Redo TBA 10 2 4 80

Wire break during RWD 8 Vibrate too freq and hard 4 Redo TBA 4 128 Redo TBA 8 3 4 96

Entanglement to ANL 8 Vibrate too freq and hard 4 Redo TBA 4 128 Redo TBA 8 4 4 128

spool


Process Potential FailurePotential Effect Sev Class Potential Causes Occ Current Process Det RPN Recommended Action

Function of Failure Control Sev Occ Det RPN

Setting wire Normal curly 6 Wire touch rubber/shaft 5 Scrap wire 4 120 6 4 2 48

Heavy curly 9 Wire touch rubber/shaft 5 Scrap Wire 4 180 9 4 2 72

Scratch 9 Wire touch rubber/shaft 5 Scrap Wire 4 180 Install rubber, wire break when

touch rubber

9 4 2 72


POTENTIAL FAILURE MODE AND EFFECT ANALYSIS ( PROCESS FMEA )

Item : Tension Arm Pulley Sensor at ANL Machine

Process Potential Potential Effect Sev Class Potential Causes Occ Current Control Process Det RPN Recommended Action

Function Failure of Failure Sev Occ Det RPN

Setting Wire Out of pulley at Scratch 9 Due to out of pulley 5 Scrap the wire 4 180 Install sensor & m/c stop auto 9 3 3 81

tension arm Touch sensor 3 Scrap the wire 4 108 Install sensor & m/c stop auto 9 3 3 81

Curly wire 10 Out of pulley 5 Scrap the wire 4 200 M/c stop after sensor detection 10 3 3 90

Touch air knife 5 Scrap the wire 4 200 Install sensor at air knife 10 3 3 90

Wire break 10 Material issue 4 Scrap the wire 3 120 Issue MDF 10 4 3 120

Tension too high 3 Reduce tension, adjustmt 3 90 Reduce tension, adjustmt 10 3 3 90

Anl temp too high 3 Reduce temp 3 90 Reduce temp 10 3 3 90

Sensor not workingDefect wire ship 10 Sensor malfunction 3 Check according to PM 4 120 Freq PM 10 3 3 90

to customer


Action Taken

Wire touch

shaft

Install rubber, wire break when

touch rubber

Install rubber, wire break when

touch rubber


Item : High Friction Rubber at Tension Arm

Action Taken

Action Taken



Action Taken

35

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.

36

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 Type C

10) 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.

37

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 fully-utilization 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.

38

♦ 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.

39

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

OK

END TAPE THE WIRE AND CUT

JOB END

NOT OK

- INFORM LEADER

- QAO TO CONFIRM

- SCRAP IF REJECT

- PROCEED IF ACCEPTED

40

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

OK

CUT THE EXTRA WIRE

JOB END

NOT OK

- INFORM LEADER

- QAO TO CONFIRM

- SCRAP IF REJECT

- PROCEED IF ACCEPTED

41

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.

42

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 Settings\chwong\Desktop\Curly study\QCC Curly study 1999\Curly wire QCC team Improvement and corrective action.ppt

C:\Documents and Settings\chwong\Desktop\Curly study\QCC Curly study 1999\QCC Curly Wire Proposal 2000.ppt

43

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: ________________________

QCC Team Chairman Date :

44

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

45

Appendix 9

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

Appendix 10

Machine

Line A Line B Line C Line A Line B Line C Line A Line B Line C Line A Line B Line C

1 4.1 3.9 3.4 4.6 4.5 3.4 3.8 3.6 3.3 4.3 3.9 3.4

2 3.6 2.5 1.2 3.5 2.5 1.5 3.4 2.3 1.1 3.5 2.6 1.7

3 2.3 3.4 3.5 3.5 3.5 3.6 3 3.1 3.3 3.5 3.5 3.7

4 3.7 3.6 3.3 3.7 3.6 3.5 3.6 3.4 3.1 3.8 3.6 3.5

5 3.6 3.6 3.6 3.7 3.7 3.6 3.1 3.4 3.3 3.5 3.9 3.5

6 3 3.3 3.4 3 3.5 3.8 2.8 2.9 3.2 3 3 3.5

7 3.5 3.3 3.4 3.3 3.7 3.6 3.2 3.1 3.2 3 3.5 3.4

8 4.3 4.2 3.8 4.5 4.2 3.9 4.2 4 3.5 4.6 4.2 3.8

9 4.2 3.3 3.7 4.3 3.5 4 4 3 3.4 4.5 3.5 3.5

10 3.7 3.6 3.3 3.9 4.2 4.1 3.5 3.3 3 4.4 4 4

11 4.1 4.4 2.2 4.5 4.4 2.5 3.9 4.2 2 4.6 4.6 2.5

12 4.7 3.1 3 5 3.4 3.5 4.5 2.9 2.8 4.6 3.4 3.6

13 3.6 1.7 3.7 3.6 2 4 3.3 1.4 3.5 3.4 1.9 3.8

14 3.3 3.8 3.8 3.3 3.7 3.7 3 3.6 3.6 3.3 4.1 4

15 3.3 2.3 1.9 3.3 2.6 1.8 3.2 2.2 1.7 3.4 2.7 1.9

16 2.9 3 3.7 2.7 3 3.9 2.7 2.8 3.5 2.9 3.1 3.8

17 3.9 2.9 3.6 3.9 2.8 3.8 3.7 2.7 3.4 4 2.8 3.7

18 3.5 3.6 3.4 3.4 3.5 3.1 3.3 3.4 3.2 3.5 3.7 3.2

21 3.3 3.6 2.2 3.4 3.7 2.2 3.1 3.5 2 3.2 4.1 2.2

22 3.5 3.6 3.7 3.5 3.7 4 3.3 3.4 3.5 3.7 3.8 4.2

23 4.7 4.6 2.2 5 4.6 2.2 4.4 4.4 2 5 4.8 2.3

24 4.2 4.2 2.6 4.5 4.2 2.5 4 4 2 4.7 4.7 2.4

25 4 4.3 2.2 3.7 3.8 2.2 3.8 4.1 2 3.9 4.3 2.2

26 4.1 4.2 3.5 4 4 3.2 3.9 4 2 4.7 4.7 2.1

27 4.2 4 2.2 4.3 3.8 2.3 4 3.8 1.9 4.5 4.5 2.3

28 4.3 4.5 2.2 4.5 4.7 2.3 4.1 4.3 2 4.7 5 2.4

29 4.3 4 2.2 4.5 4.4 2.6 4.1 3.8 2 4.7 4.6 2.7

30 4.2 4 2.2 4.7 4.4 2.6 4 3.9 2 4.9 4.7 2.7

31 4.4 4.4 3.6 4.9 4.6 3.5 4 4 1.6 4.7 4.6 2

32 3.7 4.3 2.2 4 4.1 2.9 3.5 4.1 2 4.1 4.5 2.8

33 4.6 4.4 2.2 5 5 2.7 4.2 4 1.9 4.8 4.9 2.6

34 4.2 4.2 2.2 4.3 4.2 2.3 3.9 3.9 2 4.6 4.3 2.2

35 4.7 4.7 2.2 4.7 4.7 2.7 4.2 4.2 1.9 4.4 4.9 2.2

36 4.3 4.3 4.1 4.5 3.8 4.2 4.1 4.1 2.2 4.7 4.2 2.5

37 4.3 4.3 2.2 4.3 4.2 2.4 3.9 3.9 2 4.3 4.3 2

38 4.7 5 2.2 4.5 4.8 2.4 4.5 4.8 2 5 5 2.5

39 4.5 4.3 2.2 4.8 4.5 4 4.3 4.1 2.1 5 4.5 4

40 4.1 4.4 2.2 4.1 4.1 2.3 3.9 4.2 2 4.4 4.5 2.3

41 4 3.8 2.2 4.5 3.5 4.4 3.8 3.6 2.1 4.4 4.2 2.3

42 4.5 5.3 2.2 4.5 5 2.9 4.3 5 2 4.7 5 2.7

Setting Condition Red font means more than 5 value

winding cond ; 158

Tension setting : 2.2

set count : 630

item : RN30243JFL

Parameter

End tension last layer End tension last layer gauge End stop tension machine End stop tension gauge

Appendix 11

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