On October 23rd, 2014, we updated our
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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.
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
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.
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
Mobile Current Inspection System Constraints to overcome to achieve MQ=1 %
Mobile Overall Quality Index Summary
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
We need to OVERFLOW . We decided on a new system
BIG , SPEEDY, COMPACT and STRONG
We decided to innovate using Camera
Phantom Project Hardware & Software Configuration One Stop Checking System Hardware Software N I Compact Vision System N I VB Automated Inspection v.2.0
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
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)
Development & Thema Introduction Schedule
Project Implementation Schedule- Phase 3 & 4
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
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.”
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
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.