October Development Presentation Report(New)

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Improvement group presentation slide for October 2010 progress report by Manufacturing Engineering(B) - Taiyo Yuden(Sarawak), Malaysia.

Prepared by Abdul Qaiyum Alidin

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October Development Presentation Report(New)

  1. 1. Improvement Group Process DevelopmentMalaysia Sarawak, Taiyo Yuden 16th Fiscal Year, October Monthly Presentation
  2. 2. Table of Content Development Summary  Air Press Machine Noise Reduction Activity Progress 1. Activities on October  Future activities and  Batch 1 Datsubai N2 planning Oven 1. Prototype for Shousei Outgoing(KKTY) heater resistance  Batch 1 New Datsubai 2. Plating 2 new piping Furnace Installation budget and costing  Shousei Alarm 3. Integration of recorder System chart into meb web  Web-based for Spare system Part 4. Batch 2 New Datsubai  Plating 1 new RMW Furnace Installation auto line
  3. 3. 16 Fiscal Year, October th Development Summary ACTIVITY WORK COMPLETED 16FY PROCESS PENDING ON GOING IN PROGRESS OctDATSUBAI 1 - - -GAIDEN (M) 1 - - -GAIDEN (A) - - - - SHOUSEI - 1 - -SAISANKA - - - -PLATING (1) - 1 - -PLATING (2) - - - 1
  4. 4. Improvement GroupProcess Development Activity Progress
  5. 5. Datsubai Development Activity Batch 1 Datsubai N2 Oven machine outgoing (transfer to KKTY) Oct 10 Theme Activity PIC Status WK WK WK WK 2 3 4 1 Plan Machine cleaning & replacement Improvement Group Actual Plan Machine dismantle Improvement Group Actual Batch 1 Datsubai N2 Oven Plan Machine shipment Improvement Group Machine Outgoing Actual Plan Internal transfer Actual Plan Machine setup utility work Actual Plan Done In progress Delay
  6. 6. Datsubai Development Activity  Machine transfer activity picturesThree new CF and one N2 machine internal transfer was also done The already transferred N2 oven area is now a temporarytogether while machine outgoing to KKTY is still in progress storage area for old CF before machine internal transfer(store)
  7. 7. Datsubai Development Activity New CF Installation  Replacement to old machine CF-15, CF-16, CF-17 Oct 10 Nov 10 Theme Activity PIC Status WK 2 WK 3 WK 4 WK 2 WK 3 WK 4 WK 1 WK 1 Improvement Plan Dismantle existing CF utility Group Actual Improvement Plan Transporting machine Group Actual New CF Installation Improvement Plan New CF utilities installation Group Actual Plan Machine evaluation Actual Plan Done In progress Delay
  8. 8. Datsubai Development Activity New CF Installation  Three new CF replaced CF-15,CF-16,CF-17  New MCB 175A and cabling for newer type CF  Machine evaluation method for N2-29,N2-30, N2-31, N2-32, N2-33, N2-34  9 point testing – tested and data already with EIS  O2 testing - tested and data already with EIS  Project issues  Electric supply trip during O2 testing, last evaluation method  Redo O2 testing
  9. 9. Datsubai DevelopmentActivity 9 Point Testing activity pictures N2 Oven Testing Activity In Progress
  10. 10. Gaiden(m) Development Activity  Air Press Machine Noise Reduction Aug 10 Sept 10 Oct 10 Theme Activity PIC Status WK 2 WK 3 WK 4 WK 2 WK 3 WK 4 WK 2 WK 3 WK 4 WK 1 WK 1 WK 1 Improvement Plan Modification Group Actual Plan Improvement Testing Group ActualAir Press Machine Noise Reduction Operation & Plan Monitoring & effectiveness improvement confirmation Group Actual Plan Waiting for report 1st appearance Actual Plan Done In progress Delay
  11. 11. Gaiden(m) Development Activity  Air Press Machine Noise Reduction Figure 4 Not visible, machine internal Not visible,machine internal Visible at Visible at machine machine
  12. 12. Gaiden(m) Development Activity  Air Press Machine Noise Reduction Figure 4 Not visible, machine internal Machine adjustment and test results Before AfterMachine No. Result Item Name Adjustment Adjustment (during (leadscrew) (leadscrew) testing) I-23(316) Upper 70mm 70/70 ↑ Line-A Visible at Lower 64mm 70/60 ↑ E316BJ226KL machine 60/60 NG 65/60 ↓OK I-21(316) Upper 60mm 60/65 ↓OK Line-A Lower 70mm E316BJ226KL R-9(316) Upper 65mm 65/60 ↓OK Line-A Lower 67mm E316BJ226KL P-8(316) Upper 63mm 63/60 ↓NG Line-A Lower 68mm 63/63 ↓OK E316BJ226KL
  13. 13. Gaiden(m) DevelopmentActivity Air Press Machine Noise Reduction Chip Height Measurement Method using Laser Profile kit Carrier plate point number 1 2 3 4 5 6 Total of 9 area points on carrier plate are 7 8 9 measuredRemark: Average of 5 chips height value measured from each point for recording purpose
  14. 14. Gaiden(m) Development Activity  Air Press Machine Noise Reduction Chip Height Laser Profile for item 316 Chip Height Laser Profile for item 212 Before Before Chip modification modification ChipHeight(μm) After After Height(μm) 1.25 modification modification 1.55 1.2 1.5 1.15 1.45 1.1 1.4 1.05 1.35 1 1.3 0.95 1.25 0.9 1.2 one two three four five six seven eight nine Plate Point one two three four five six seven eight nine Plate Point A record of chip height or protrusion data pattern in graph Remark: Measured values before and after modification has already verified by SE and implemented for their new EMS
  15. 15. Gaiden(m) DevelopmentActivity Air Press Machine Noise Reduction  First appearance record
  16. 16. Shousei Development Activity  O2 Recordered Chart & Alarm System Installation Oct 10 Nov 10 Theme Activity PIC Status WK 2 WK 3 WK 4 WK 2 WK 3 WK 4 WK 1 WK 1 Plan Improvement Prototype & Setup Improvement Group ActualO2 Recordered Chart & Alarm Plan Further Development & Testing Improvement Group System Installation Actual Machine running for Plan Improvement and Production testing Operation Group Actual Plan Done In progress Delay
  17. 17. Shousei Development Activity O2 Recordered Chart & Alarm System Installation  New feature  Monitor machine abnormality with 2 minutes delay  Automatic alarm notification by e-mail  Raw data(*.DAD) automatic backup to FTP NAZ  Remarking in Recordered Chart via Web Message function  Project issues  Network or server sometimes was not stable, hence Recordered Chart return FTP error  Stop and start sampling
  18. 18. Shousei Development Activity Recording/remarking from web activity pictures Message panel Web interface for remarking purpose
  19. 19. Shousei Development Activity  Recording/remarking from web activity pictures View through historical data control and the new web window will appear like on the leftSample of record when recorded messagevia web message panel
  20. 20. Shousei Development Activity Web Message Log record when using web message activity pictures Message Log Record
  21. 21. Shousei Development Activity Alarm Setup activity pictures Alarm setting option Installed with energize and hold option setup alarm
  22. 22. Shousei Development Activity  FTP Setup activity picturesAutomatic Event Setting(FTP Sending Time) Automatic Data Saving Setting
  23. 23. Shousei Development Activity FTP Setup activity pictures FTP Account and Path Directory Setting
  24. 24. Shousei Development Activity  Raw data(*.DAD) automatic backup to FTP NAZ Server activity pictures  Activity picturesData storage for 1 year and moreRemark:CF storage capacity 2G, about 1 yearand less.Internal memory, limited to about100 sample recent data.
  25. 25. Shousei Development Activity Issues during testing activity pictures Please also do check Error Log Record Due to network connection or server issues, problem can be solved by stopping and starting data sampling.
  26. 26. Shousei Development Activity FTP Log record/reference activity pictures No. or Code, refer to Yokogawa User’s Manual FTP Log Record
  27. 27. Shousei Development Activity Alarm Setup activity pictures Alarm Delay Setting High and Low Limit with delay Alarm setting option
  28. 28. Shousei Development Activity E-Mail Notification activity pictures E-mail Server Setting Sender E-mail Setting
  29. 29. Shousei Development Activity E-Mail Notification activity pictures Recipients E-mail Setting
  30. 30. Shousei Development Activity Activity pictures Alarm notified in E-mail
  31. 31. Shousei Development Activity Activity pictures Periodic data in E-mail
  32. 32. Plating(1) Development Activity .Facilities planning progress schedule Sept-10 Oct-10 Nov-10 Activities w1 w2 w3 w4 w1 w2 w3 w4 w1 w2 w3 w4 Primary Works plan ( Power Supplycompress air and city water. ) actual New R.O tank & D.I tank plan piping. actual plan Installation new D.I plant actual plan Manual line dismantle actual Renovation of ceiling(install plannew ceiling height and re-install new lighting and M&E system actual plan actual In progress Delay
  33. 33. Plating(1) Development Activity  Dismantling Activity picturesDismantling line progress Dispose part Renovation of ceiling Segregating dispose part and spare part
  34. 34. Plating (1) Development ActivityNew D.I plant plating 1 layout This areaPlating manual line New D.I plant area
  35. 35. Plating1(RMW) Development Activity .Facilities planning progress schedule Activity pictures New DI Plant Area DI Plant Installation In Progress New DI Plant Control Panel
  36. 36. Plating1(RMW) Development Activity.Facilities planning progress schedule Machine adjustment and DI Plant Setup in test results Progress
  37. 37. Improvement GroupProcess DevelopmentFuture Activity and Planning
  38. 38. 16 Fiscal Year th Future Activity and Planning Web-based system for spare part purpose integration with ME-B existing system(ex. Yokogawa Recorder) Spare Part Inventory System Machine incoming & development process  Plating(1) auto line – Facilities planning progress schedule, new D.I plant layout.  Datsubai – Confirmed total of 8 machines out, 1st batch expected 4 machines out on October and later 2nd batch another 4 machines out on November.
  39. 39. 16 Fiscal Year th Future Activity and Planning Web-based system planning Sept 10 Oct 10 Theme Activity PIC Status WK 2 WK 3 WK 4 WK 2 WK 3 WK 4 WK 1 WK 1 Outline project requirement Plan Improvement Group Prepare activity schedule Actual Plan Research on project requirement Improvement Group Actual Plan Web-based system for spare part Web development Improvement Group Actual Plan Testing Improvement Group Future Activity Progress Actual Plan Proposal presentation Improvement Group Actual Plan Done In progress Delay
  40. 40. 16 Fiscal Year th Future Activity and Planning Spare Part Web-based System  Objective: Item or equipment records for internal reference  Detail of equipment specification, usage, used frequency, lifespan, price, storage area and rack location, etc.  Its purpose is to assist in searching equipments, avoid confusion related to equipment and deeper understanding of equipment usage with their relationship in machine operation.
  41. 41. 16 Fiscal Yearth Future Activity and Planning Spare Part Web-based System  Installation and setup  A computer system/server with network infrastructure  Low cost system using free and open source project(PHP, MySQL, Apache)  Open source CMS(Content Management System), for example Joomla, CMSMadeSimple,  Windows Operating System platform  Coding and development process with Notepad++
  42. 42. 16 Fiscal Year th Future Activity and Planning Spare Part Inventory System  Objective: Processing inventory data for internal processes  Integration with currently under development system or new system  Incoming, outgoing, stock balance, by date, insert and delete item,
  43. 43. Plating(1) Development Activity  Plating 1(RMW) Auto Line Setup schedule Nov 10 Dec 10 Theme Activities 1st wk 2nd wk 3rd wk 4th wk 1st wk 2nd wk 3rd wk 4th wk Plan Machine Move In Actual Plan Structure / Frame Setup ActualEpNi-Sn Auto Machine Setup Machine Setup Plan Future Activity Progress Schedule Actual Plan Barrel Sensor and Positioning Check Actual Plan Test Run And Monitoring Actual Plan Done In progress Delay
  44. 44. Plating(1) Development Activity  Plating 1(RMW) Auto Line Setup schedule Nov 10 Dec 10 Theme Activities 1st wk 2nd wk 3rd wk 4th wk 1st wk 2nd wk 3rd wk 4th wk Plan Machine Move In Actual Plan Structure / Frame Setup ActualStCu-EpCu Auto Machine Setup Machine Setup Plan Future Activity Progress Schedule Actual Plan Barrel Sensor and Positioning Check Actual Plan Test Run And Monitoring Actual Plan Done In progress Delay
  45. 45. Improvement GroupProcess Development Thank You.

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