• Save
User Solution - NI Malaysia - James Lai - Visiont - cvs - Q2 2005
Upcoming SlideShare
Loading in...5
×
 

Like this? Share it with your network

Share

User Solution - NI Malaysia - James Lai - Visiont - cvs - Q2 2005

on

  • 1,551 views

http://www.youtube.com/profile_videos?user=victormieres

http://www.youtube.com/profile_videos?user=victormieres

Statistics

Views

Total Views
1,551
Views on SlideShare
1,551
Embed Views
0

Actions

Likes
0
Downloads
0
Comments
0

0 Embeds 0

No embeds

Accessibility

Categories

Upload Details

Uploaded via as Microsoft PowerPoint

Usage Rights

© All Rights Reserved

Report content

Flagged as inappropriate Flag as inappropriate
Flag as inappropriate

Select your reason for flagging this presentation as inappropriate.

Cancel
  • Full Name Full Name Comment goes here.
    Are you sure you want to
    Your message goes here
    Processing…
Post Comment
Edit your comment

User Solution - NI Malaysia - James Lai - Visiont - cvs - Q2 2005 Presentation Transcript

  • 1. Project Phantom S.Thayalan. 9 th Oct 2004 Polymatech (M) Sdn. Bhd. NOW! One Checking System
  • 2. Objective
    • To reduce “OVERFLOW” rejection from parts supply (by process) to Assembly and from Assembly to GI.
    • “ ZERO” customer claim for Cosmetic Rejection from Customer.
    • To reduce dependency on man.
    • Avoid using non-qualified man.
    • Flexible, Reliable, Standard Inspection Method.
    • Integrated Inspection System connected to Production Information System (PIS) and Quality Information System (QIS) system for fast feedback reaction.
  • 3. Mobile Current Inspection System Image Flow Single Injection Base Coat UV Coat Reverse Printing Pad Printing Gate Punching Inspection & Middle Inspection Weld Line Sink Mark Oil Mark FM/ Fiber Spray Dot FM Fiber Spray Dot FM Fiber Char NG Colour FM Fiber Design Char NG Colour FM Fiber Design Gate Burr Over Cut Under Cut FM FIber IPQC 1 Sampling AQL 0.4 Pre Assembly Assembly VIS Checking Design Key Rotated & Key Missing IPQC2 KKL Insp GL IPQC3 Guarantee Inspection Inspection Operator In Process Quality Control Operator – IPQC1 NG NG NG NG NG NG
  • 4.
    • Variance in Inter Shift Operators.
      • PTM manpower turnover is averagely 10%-15% each month where 25% of these operators are less than 3 months at PTM
    • High absentism affects productivity
      • Need to use different operators, this will incur overtime and Overtime operators sometimes not 100% qualified and doing overtime can suffer from fatigue
    • High Cycle Time and not consistent
      • Parts cannot be supplied smoothly to next process, causing very poor results in Line Balancing of the full process. This also accumulates PWIP before inspection.
    • Over/Under Reject
      • Highly cosmetic parts requires experienced operators to make accurate judgment and failure can result in both over reject or in worst case under reject.
    • High Man-hour holding/cost
    • Limited Space
    Mobile Current Inspection System Constraints to overcome to achieve MQ=1 %
  • 5. Mobile Overall Quality Index Summary
  • 6. Mobile Current Overflow Quality Index Analysis NG Overflow to Assembly Amount RM 9.9k / ¥ 309k every month. Average about RM 118k / ¥ 3.9million a year
    • 48% of Assembly Rejection is
    • due to overflow NG’s
    2. Thus, just by reducing overflow we can immediately reduce MQ to 2.49%
    • We can convert 2.88% overflow
    • to profit increasing our profit margin
    Overflow! Overflow!
  • 7.
    • We need to OVERFLOW . We decided on a new system
    • BIG , SPEEDY, COMPACT and STRONG
    • We decided to innovate using Camera
    • Inspection System.
    PHANTOM
  • 8. Phantom Project Hardware & Software Configuration One Stop Checking System Hardware Software N I Compact Vision System N I VB Automated Inspection v.2.0
  • 9. Mobile Innovated Inspection System Image Flow- Phase 1 Single Injection Base Coat UV Coat Reverse Printing Pad Printing Gate Punching Middle Inspection IPQC 1 Sampling AQL 0.4 Pre Assembly Assembly VIS Checking Design Key Rotated & Key Missing IPQC2 KKL Insp GL IPQC3 Guarantee Inspection Inspection Operator Offline Setting OK NG Parts Control Centre Parts Control Centre (supermarket) to Pre-Assy Using e-Kanban™ Cell Parts Inspection Camera IPQC1 100% Inspection
  • 10. Phantom Project Inspection Requirements Inspection Requirement Cosmetic Inspection Key Missing Rotated Shape Torn Dimension Design Colour Character Position Foreign Matter Scratch Mechanical Inspection Using Match Pattern Using Find Straight Edges Using Match Pattern Using Match Pattern Using Caliper Using OCR/Match Pattern Using OCR/Match Pattern Using Straight Line Using Count Pixel Fluctuations/Lighting Vision System OK Vision System Under Testing Checking Items Software Method Using OCR/Match Pattern 1. Checking Cycle Time= 4mili seconds, Average = 3.5parts/sec (IEEE 1394 Fire Wire Technology) Real-Time Data Transfer 2. Unlimited Region for checking. Capacity per hour 10,800pcs (based on 4ms per piece)
  • 11. Development & Thema Introduction Schedule
  • 12. Project Implementation Schedule- Phase 3 & 4
  • 13. 6. Cost Analysis- COPQ & COQ Cost
    • Inspection Labour Cost in PTM
    • (Keypad Dept. 3 rd Quarter Results)
    2. Inspection Overtime Cost in PTM (Keypad Dept. 3 rd Quarter Results) 3. Overflow NG Amount in PTM (Keypad Dept. 3 rd Quarter Results) TOTAL COST : RM 146,700 / ¥ 4,584,375 per month
  • 14. Cost Analysis- How much we can Save? “ PTM/Polymatech Group can save average RM 110,000/month that equals to RM 1.32 million / ¥ 40.9million in 1 year.”
  • 15. Cost Analysis-Return of Investment (ROI) INVESTMENT COST (est*) : RM 70,000 (3 units capability) SAVINGS (est*) : RM 110,700 Return Of Investment (ROI)= _____________________ Investment Cost -RM 70,000 Savings -RM 110,700 = 19 working days “ PTM/Polymatech Group can save average RM 110,000/month that equals to RM 1.32 million / ¥ 40.9million in 1 year.” * Currently no purchase made. Only trial run
  • 16. Conclusion
    • With the successful implementation of this system we can look forward to achieve our target towards MQ=1%
    • PTM can use this system for Mobile Unit in plant 1 and later migrate to Plant 2 where Plant 2 MQ by default is 1%.
    • Huge amount of savings and successful muda removal tool.
    • We will consider to implement in Connector, Hybrid Damper & General Rubber wherever applicable.
  • 17. Thank You… towards MQ-1