Advance Innovation Group- Lean Six Sigma Project on Cycle time reduction by

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This Lean Six Sigma Project done by student from Advance Innovation group which is posted to provide for benchmarking and best practices sharing purposes.

This is a Student project on Reducing Cycle time,submitted for Six Sigma Certification.

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Advance Innovation Group- Lean Six Sigma Project on Cycle time reduction by

  1. 1. Cycle time reduction in DVDR Challenger-II line
  2. 2. Define
  3. 3. Project CharterProject Title :To reduce the cycle time of Challenger-II lines from 2.3 sec to 1.9secBusiness Case Opportunity StatementManufacturing Cost of DVD-R is high, which is required to bereduced by reducing the cycle time of CH-II lines.Average production per line per day of Challenger-IIlines during April’11~ Sept’11 is 32k.We have toimprove average production by reducing the cycle timefrom 2.3 to 1.9sec, which will result in gain of 6k no. ofdiscs / line / day, providing a net profit of 4.17 crores.Goal statement Project scopeMetric Current level Goal /TargetTarget date Process under improvement:Starts with – PC feeding to IMMEnds with – Final disc at receiver areaNo of lines – All Challenger-II DVDR (20 Lines)Cycle time 2.3sec 1.9sec30thJan’12’Project plan Team SelectionPhase Start End Remarks Champion: Mr. ShishirDefine 1stSept’11 15thSept’11 Project Leader : Mr. ABC (Line – Process)Measure 16thSept’11 30thSept’11 Member : Mr. AB (Line – Process)Analyze 01stOct’11 30thOct’11 Member : Mr. PQ ( IMM – Process)Member: Mr. QS (IMM – Process)Improve 01stNov’11 15thDec’11 Member : Mr. NS (Line -Maintenance)Member : Mr. LM(Line – Maintenance)Control 15 Dec’11 30thJan’12 Member : Mr. JP(Production)Member : Mr. PK(Quality)
  4. 4. Critical to quality and critical to process chartCRITICAL BUSINESSREQUIREMENTCRITICAL TO PROCESSTimely delivery of productVOICE OF BUSINESS BUSINESS ISSUECycle time <= 1.9 andproductivity should be>=38000Cycle time should be low,productivity should meet / cross ABPtargetsCost per unit disc should be lowProductivity should meet / cross ABPtargetProductivityHigh cost per unit discLow CRDDHigh ProductivityLow Manufacturing cost
  5. 5. SIPOCS I P O CBayer piavon Dried PC feeding to IMMSumitomo/Netstal Moulding IMM (Inline / Off line) Blank activeFan Cooling Disc temp reduceSony Dye Dye coating Active dye coating discEta Scanner Scanner Dye scanner Disc gradingBlank ink Printing Disc IdentifcationHeater Drying Dye dry on discChooksi Silver/Gold Sputtering Sputter Active discMethyl Lactate Edge washing Disc outer edge cleanPancure/ Glue/ Mercury lamp Bonding & UV curing 2 disc 0.6mm bonded & cureEta Scanner Scanner Final Scanner Final disc gradingMBIL Grade wise Spindle Receiver Table DVDR 16X +- RSONY
  6. 6. ARMIKeyStakeholdersARMI WorksheetDefine Measure Analyze Improve ControlStakeholders--CEOI I I I ISponsor-VP I I I I IChampion-AVP I & A I & A I & A I & A I & AMBB A & I A & I A & I A & I A & ILBB I & R I & R I & R I & R I & RProcessManagerI & M I & M I & M I & M I & MBB R & M R & M R & M R & M R & MTeam Members M M M M MCommunication PlanInformation Or Activity Target Audience Information Channel Who WhenProject Status Leadership E-mails Binny BI-WeeklyTollgate Review BB,LBB,MBB & Champion E-mails or Meetings As per Project PlanProject Deliverables or Activities Members Emails, Meetings WeeklyA – Approval of team decisions I.e., sponsor, business leader, MBB.R – Resource to the team, one whose expertise, skills, may be needed on an ad-hoc basis.M – Member of team – whose expertise will be needed on a regular basis.I – Interested party, one who will need to be kept informed on direction, findings.
  7. 7. TOP DOWN CHARTTOP DOWN CHARTMANUFACTURE DVDR (16X+/-R) DISCS IN CH-II LINESCIMM-A( IN-LINE )Injecting Homogenousmixture into MouldBlank Active Disc placedfrom mould by transferhandler to I/P pin of InlineprecoolerCoining processMould OpeningPC supply from PiovanStamper LoadingMould ClosingDye conveyor movesdisc tow ards dyescanningSpinning of Dye layerDisc moves back ontodye conveyor by PTGhandlerDiisc from Dye Conveyorplaced inside dye cupsby PTG handlersDye needle dispense dyeas per Apply dyeprogramDisc moves to DyeSection( Dye conveyorby transfer handlerDisc from INLINEprecooler moves tocooling conveyor fromprecooler transferDisc from BUFFER loadson cooling conveyor byBuffer Loading/UnloadinghanlderStepping of coolingconveyorDisc loads in stackerspindleStacker spindle loads online MANUALLY at BufferLocationInjecting Homogenousmixture into MouldCoining processMould OpeningBlank Active Disc placedfrom mould by transferhandler to I/P pin ofprecoolerPC supply from PiovanStamper LoadingMould ClosingDYE COATINGIMM-A( OFFLINE )COOLING
  8. 8. TOP DOWN CHARTTOP DOWN CHART (contd.)MANUFACTURE DVDR (16X+/-R) DISCS IN CH-II LINESC CDYE SCANNERScanner Tansfer handlerpicks disc and place it onscanner chuckscanner scans disc forvarious Global andBottom defectsGrade the disc and placeit on Printer chuckFeed Table gets dryeddisc from metallizerconveyorand places thedisc onto I/P pins ofmetallizerFrom load lock chamber,sputtered disc moves tofeed table for edgew ashing conveyorsputtered Disc movesfrom sputter chamber toload lock chamberMetallizer handler picksdisc and places insidethe load lock chamberDisc moves from loadlock chamber to sputterchamberSputtering of120nm silveron Disctakes placeMETALLIZERDryer I/P handler picstw o disc at L/R Suckerfrom Dye conveyorOutput handler picks thedisc from dryer andplaces on the metallizerconveyorhandler w aits for thethird discM- sucker pics the discand then I/P handlerplaces the disc inside thedryerDisc dried at a tempof 90degreesDRYERPRINTERPrinter prints the discinformation w ith a laserDifferent printing is doneaccording to the grade ofdisc from dye scannerTransfre handler placethe disc back on dyeconveyor
  9. 9. TOP DOWN CHARTTOP DOWN CHARTMANUFACTURE DVDR (16X+/-R) DISCS IN CH-II LINESCFinal Disc to ReceiverFINAL SCANNERUV CURINGEDGE WASHING BONDINGFinal scanner handlerplaces disc on scannerchuckFinal scanner scans discfor various Global,Bottomand Top defectsAfter grading the disc, itplace it on the respectivespindle at final receiverstationDisc Inside UV platesmoves under UV lampUV lamp exposes UVradiation onto disc for1300msec and pow er at3500 to cure the discUV cured disc moves outof UV lamp assembleyFlip Handler picks andplace at final scannerhandlerSpinning of disc takesplaceDisc moves from spiinerto UV plate by spinningUnload handlerCapillary ation takesplacesDisc pick and placedinside spin cup by spincup load handlerBonding chuck rotates atpredefined RPMBonding Unload handlerpicks the disc and placeit on capillary pinEW conveyor moves theEW disc tow ardsBonding feed tablePTG handler picks discfrom edge w ashing (EW)conveyor and placesinside the EW cupEdge w ashing ofsputtered disc doneaccording to profieEW disc picks and placedback on conveyor pin byPTG handlerBonding Top Flip handlerpicks the dummy fromBonding feed tableBottom load handler picksEW disc and placed in onbonding chuckBonding Chuck rotates toBonding positionBonding Freew heel picksDummy and placesabove the bonding chuckBoth bonding needlemoves inside the gapbetw een dummy and EWactive disc
  10. 10. FUNCTIONAL DEPLOYMENT CHARTFUNCTIONAL DEPLOYMENT CHARTDisc loads in stackerspindlePC supply from PiovanInjecting Homogenousmixture into MouldStamper LoadingMould ClosingCoining processMould OpeningStacker spindle loads online MANUALLY at BufferLocationDisc from INLINE precoolermoves to cooling conveyorfrom precooler transferhandlerBlank Active Disc placedfrom mould by transferhandler to I/P pin of InlineprecoolerIMM -INLINE LINE-PROCESS IMM- OFFLINE QUALITYSUB PROCESSSTARTA-1A-2A-3A-4A-5A-6A-7A1-1A1-2A1-3A1-4A1-5A1-6A1-7A1-8A-8A-9Cont.
  11. 11. FUNCTIONAL DEPLOYMENT CHART (Cont.)IMM -INLINE LINE-PROCESS IMM- OFFLINE QUALITYSUB PROCESSDisc moves to Dye Section(Dye conveyor by transferhandlerDisc from BUFFER loads oncooling conveyor by BufferLoading/Unloading hanlderStepping of cooling conveyorDisc from Dye Conveyorplaced inside dye cups byPTG handlersDye needle dispense dye asper Apply dye programDisc moves back onto dyeconveyor by PTG handlerSpinning of Dye layerDye conveyor moves disctowards dye scanningScanner Tansfer handlerpicks disc and place it onscanner chuckscanner scans disc forvarious Global and BottomdefectsGrade the disc and place iton Printer chuckA-10A-11A-12A-13A-14A-15A-16A-17A-18D-1A-19NOYEScontdIf problem occursduring dye dispensing,then action will betaken at A-14,otherwise we will workon A-15
  12. 12. FUNCTIONAL DEPLOYMENT CHART (Cont.)IMM -INLINE LINE-PROCESS IMM- OFFLINE QUALITYSUB PROCESSPrinter prints the discinformation with a laserDifferent printing is doneaccording to the grade ofdisc from dye scannerTransfer handler place thedisc back on dye conveyorDryer I/P handler pics twodisc at L/R Sucker from Dyeconveyorhandler waits for the thirddiscM- sucker pics the disc andthen I/P handler places thedisc inside the dryerDisc dried at a temp of 90degreesOutput handler picks thedisc from dryer and placeson the metallizer conveyorFeed Table gets dryed discfrom metallizer conveyorandplaces the disc onto I/P pinsof metallizerMetallizer handler picks discand places inside the loadlock chamberA-20A-21A-22A-23A-24A-25A-26A-27A-28A-29contd
  13. 13. FUNCTIONAL DEPLOYMENT CHART (Cont.)IMM -INLINE LINE-PROCESS IMM- OFFLINE QUALITYSUB PROCESSDisc moves from load lockchamber to sputter chamberSputtering of 120nm silveron Disc takes placesputtered Disc moves fromsputter chamber to load lockchamberFrom load lock chamber,sputtered disc moves to feedtable for edge washingconveyorPTG handler picks disc fromedge washing (EW)conveyor and places insidethe EW cupEdge washing of sputtereddisc done according toprofileEW disc picks and placedback on conveyor pin byPTG handlerEW conveyor moves the EWdisc towards Bonding feedtableBonding Top Flip handlerpicks the dummy fromBonding feed tableBottom load handler picksEW disc and placed in onbonding chuckBonding Chuck rotates toBonding positionA-30A-31A-32A-33A-34A-35A-36A-37A-38A-39A-40contd
  14. 14. FUNCTIONAL DEPLOYMENT CHART (Cont.)IMM -INLINE LINE-PROCESS IMM- OFFLINE QUALITYSUB PROCESSBonding Freewheel picksDummy and places abovethe bonding chuckBoth bonding needle movesinside the gap betweendummy and EW active discBonding chuck rotates atpredefined RPMBonding Unload handlerpicks the disc and place iton capillary pinCapillary action takesplacesDisc pick and placed insidespin cup by spin cup loadhandlerSpinning of disc takesplaceDisc moves from spniner toUV plate by spinning UnloadhandlerDisc Inside UV plates movesunder UV lampUV lamp exposes UVradiation onto disc for1300msec and power at3500 to cure the discUV cured disc moves out ofUV lamp assembleyA-41A-42A-43A-44A-45A-46A-47A-48A-49A-50A-51contd
  15. 15. FUNCTIONAL DEPLOYMENT CHARTIMM -INLINE LINE-PROCESS IMM- OFFLINE QUALITYSUB PROCESSFlip Handler picks and placeat final scanner handlerFinal scanner handler placesdisc on scanner chuckFinal scanner scans disc forvarious Global,Bottom andTop defectsAfter grading the disc, itplace it on the respectivespindle at final receiverA-52A-53D-2STOPYESNODepending on thetype of problem,Action will be takenon respectiveprocess / subprocess
  16. 16. PROCESS FLOW DIAGRAM OF CH-II AT 2.3 sec ( Before Quick win)IMM A (Inline)--3.0SecIMM A (offline)--3.0SecCOOLINGCONVEYOR1.96 secDYE COATER 2.1 secDYE SCANNER 1.8 secPRINTER 1.8 secDRYER 2.1 secMETALLIZER 2.1 sec EDGE WASHING 1.96 sec BONDING 2.0secUV CURING 2.0secFINAL SCANNER 2.0secFor 1.9 Cycle time : IMM( Inline / Offline ) <= 2.5sec , and all other blocks <=1.9sec
  17. 17. Quick Wins (Cycle time)SOURCE CONCERN / ISSUEPOTENTIAL QUCIK WINOPPORTUNITY (SOLUTION)EASY TOIMPLEMENTFAST TOIMPLEMENTCHEAP TOIMPLEMENTWITHIN THETEAMCONTROLEASYREVERSIBLEIMPLEMENT(Y/N)Clamping time / Mouldtemperature to be reducYCooling Time to be reduce YDye Transfer handler /PTG handler / dryermovement / Bondinghandlers speed / UVplates movementSpeed of motors and drivesincreasedYEdge washingprocessing TimeProcessing Time reduce bymodifying the profileYUV Curing Time UV curing Time reducion YIMM - Cycle TimeFunctionalDeploymentChart
  18. 18. Quick Wins Implementation PlanS.NO QUICK WIN ACTIVITIES RESPONSIBILITIES START DATETARGET DATEOF COMPLETIONACTUAL DATEOF COMPLETIONSTANDARDIZATIONOF COMPLETION1Clamping time /Mould temperatureThird / Fourth Clamping timereduced from 1.0sec to 0.7secAnuj Katiyar / Aditya 5th sept11 10th Sept11 13th sept112 Cooling TimeCooling time reduced from1.9sec to 1.4 secAnuj Katiyar / Aditya 5th sept11 10th Sept11 13th sept113Speed of motors anddrives increasedSpeed of motors and drivesincreased from 70% to 90%NS Rao 8th Sept11 10th sept11 12th Sept11Settings displayed online4Edge washingProcessing TimereducedNew edge washing profile wasdeveloped to reduced the overall processing time from1750msec to 1100msecRuchir / Sharad 5th sept11 15th Sept11 23nd sept11Window revised,technical reportpublished5 UV curing TimeUV Curing time reduced from1400 to 1000msec byincreasing the base/ nominalpower and reduce the exposuretimeRuchir / Piyush 5th sept11 15th Sept11 25nd sept11Window revised,technical reportpublishedMoulding WindowRevised -ISOcontrolled throughTQM
  19. 19. Quick Wins Implementation ResultsS.NO QUICK WIN QUICK WIN IMPLEMENTATION RESPONSIBILITIESINITIAL CYCLETIMEGAINCYCLE TIMEAFTERIMPLEMENTATIONREMARKS1Clamping time /Mould temperatureThird / Fourth Clamping timereduced from 1.0sec to 0.7secAnuj Katiyar / Aditya 3.0 sec 0.3 sec 2.7 sec2 Cooling TimeCooling time reduced from 1.9secto 1.4 secAnuj Katiyar / Aditya 3.0 sec 0.5 sec 2.5 sec3Speed of motors anddrives increasedSpeed of motors and drivesincreased from 70% to 90%NS Rao NA NA NAHandlingSpeeds weresynchronisedwith variousprocess4Processing TimeEdge washing isreduced by modifyingthe profileNew edge washing profile wasdeveloped to reduced the over allprocessing time from 1750msec to1100msecRuchir / Sharad 2.0 sec 0.55 sec 1.5sec5 UV curing TimeUV Curing time reduced from 1400to 1000msec by increasing thebase/ nominal power and reducethe exposure timeRuchir / Piyush 2.0 sec 0.4sec 1.6secLearning fromCH-I andOrigins Dyecomet projects
  20. 20. PROCESS FLOW DIAGRAM OF CH-II AT 2.05 sec ( After Quick win)IMM A (Inline)—2.5SecIMM A (offline)—2.5SecCOOLINGCONVEYOR1.96 secDYE COATER 2.1 secDYE SCANNER 1.8 secPRINTER 1.8 secDRYER 2.1 secMETALLIZER 2.1 sec EDGE WASHING 1.7 sec BONDING 2.0secUV CURING 1.7secFINAL SCANNER 2.0sec
  21. 21. MeasureaMeasure
  22. 22. Cause and Effect DiagramFinal scannerCoolingBondingDy e coat erMet allizerDry erSlider speedmov ementStacks up and dow nDry er w aiting timeDry ing timeplatter up dow n timeDisc handling timeLoad lock speedLoad lock mov ementVenting timeRoughing timeSputtering timeNo of dy e cupDy e handling timestapling timeDy e conv ey orDy e processing timeI D cap mov ementCapillary delay timedow n mov ementBonding head uptimeBonding processingmov ementdirection of conv oy erbufferDisc loading fromStaping frequencyStepping Timehandlers timePick and placeDisc scanning timedelayScanning ang rotationDisc handling timeCause-and-Effect Diagr am
  23. 23. Cause and Effect MatrixSectionOutPut Indicator -Cycle Time (10)Total9 903 309 903 309 909 901 101 103 301 109 903 303 309 903 301 109 903 303 301 103 301 103 309 903 303 303 303 30DryerMetallizerBondingSlider speedSputtering TimeRoughing TimeVenting TimeLoad Lock MovementFeed table speedCoolingConveyorDye CoatingFinal ScannerDirection of Conveyor MovementDye Processing timeDye Conveyor Stepping TimeDye handling TimeInput IndicatorsStepping timeStepping FrequencyDisc loading from BufferNo of Dye CupsDisc handling timescanning and rotational delayDisc scanning TimePick and Place handlers TimeDrying TimeDryer waiting TimeStacks Up/ Down MovementDisc handling TimePlatter Up/ Down MovementID Cap MovementBonding processing TimeNeedle MovementBonding head Up/ Down MovementCapillary delay table
  24. 24. YY1Y2Y3Y4Y5Y6CYCLE TIMECH-II LINESCOOLING CONVEYOR CYCLE TIMEDYE COATER CYCLE TIMEDRYER CYCLE TIMEMETALLIZER CYCLE TIMEBONDING CYCLE TIMEFINAL SCANNER CYCLE TIMEX1X2X3X4X5X6X7X8STEPPING TIMEDISC LOADING FROM BUFFERDYE PROCESSING TIMEDYE CONVEYOR STEPPING TIMEDRYER WAITING TIMESPUTTERING TIMEBONDING PROCESSING TIMEDISC SCANNING TIMEPrioritized Y / X’s
  25. 25. OPERATIONAL DEFINITION ( Y1 & Y2)Dye coater : Dye coating is the Process in which a thin film of dye solution (consist ofDye powder- solute and TFP-Solvent) is coated over active blank substrate.Dye coating process consist of apply dye and spinning profileAmbient condition inside dye coater:-Humidity = 35~45% Temperature= 27 degree CelsiusAirflow = 0.9~1.2 m/sec Exhaust = 0.8 ~ 1.5 m/secDye coater cycle Time: The cycle time is the time duration between the two consecutive dye coateddisc This data is available at the Dye coating control panel. To collect this data we need to note thetotal process time from Dye coating control panel. The Process person will be responsible forcollecting this data.COOLING CONVEYOR :It is a conveyor which transports the blank active disc from precooler stationto dye coater section. During movement disc gets cooled air (27C) from the perforated slots belowthe conveyor.Cooling Conveyor cycle Time: The cycle time is the time duration between the two consecutive blankactive disc which is transported by the conveyor. This data is collected by stop watch. The Processperson will be responsible for collecting this data.
  26. 26. OPERATIONAL DEFINITION ( Y3 & Y4 )DRYER :Dryer is a unit used for drying of dye coated disc. This process is used to evaporate the TFPsolution from Dye coated disc.Temp of Dryer for Drying Process: 90 deg CelsiusDRYER Cycle Time: This is time duration between two consecutive disc at Dryer output .The cycle time of theAnnealing unit can be note down from stop watch at the output of dryer unit. This data will be collected by theLine Process person.METALLIZER: Metalizing is the method of creating thin reflective layers on any substrate. Asource (Target) material is intensively bombarded by ions, thus atoms/ particles are knocked outof the material surface. Those particles settle down on a substrate and thus form a thin reflectivelayerMETALLIZER cycle Time: The metallizer cycle time is the average time between the two consecutive cycle ofthe metallizer.The Cycle time comes at the screen of the metallizer control panel .During the time of recordingthe line should be running in continuous mode with no alarms as if any alarms comes during the recording thecycle time data will be changed. This data will be collected by the Line Process person.
  27. 27. OPERATIONAL DEFINITION ( Y5 & Y6 )BONDING: Bonding is the process of binding Active (edge washed) disc with Dummy substratewith a bonding lacquer, which is a monomer which converts into cross linked polymer under theexposure of UV radiation.Bonding process consist of Lacquer application , Capillary action and spinningBONDING CYCLE TIME: The bonding cycle time is the average time between the two consecutive cycle of thebonding process after spinning of lacquer from disc. The Cycle time comes at the Main screen of the line.During the time of recording the line should be running in continuous mode with no alarms as if any alarmscomes during the recording the cycle time data will be changed. This data will be collected by the Line Processperson.FINAL SCANNER: It is a reflection type scanner, used to check the quality the finished discbefore the final receiver table. It checks the disc for various Top, Bottom and Global defects andclassify / grade the disc accordingly.FINAL SCANNER cycle Time: The final scanner cycle time is the average time between the two consecutivecycle of the scanning of disc at final scanner. The Cycle time comes at the screen of the final scanne .Duringthe time of recording the line should be running in continuous mode with no alarms as if any alarms comesduring the recording the cycle time data will be changed. This data will be collected by the Line Processperson.
  28. 28. DATA MEASUREMENT PLAN ( Y )Performancemeasure (Y’s)OperationaldefinitionData sourceand locationSamplesizeWho willcollect the dataWhen willdata becollectedHow will data becollectedCoolingConveyorAs defined inoperationaldefinitionStop Watch 90 Ruchir 22ndSept’11 15readings/shift/dayDye CoaterDye coaterscreen90Piyush 22ndSept’11 15readings/shift/dayDryer Stop Watch90Ruchir 22ndSept’11 15readings/shift/dayMetallizerMetallizerScreen90Vipin 22ndSept’11 15readings/shift/dayBonding Bonding- LineMain screen90Sharad 22ndSept’11 15readings/shift/dayFinal scannerFinal scannerscreen90Piyush 22ndSept’11 15readings/shift/day
  29. 29. OPERATIONAL DEFINITION ( X1’s )Input Molder /precoolerBuffer L0Cooling ConveyorPosition APosition BAs shown in diagram, Stepping time of Cooling conveyor isthe time taken to move from position A to Position B by thepin carrying blank active disc.STEPPING TIME OF COOLING CONVEYOR: It is the time taken by cooling conveyor pin carrying blank activedisc running in auto mode to move from one position to very next position. It is measure in seconds bystopwatch.
  30. 30. OPERATIONAL DEFINITION ( X2 )DISC LOADING FROM BUFFER: Challenger-II lines has two kinds of feeding of Blank disc . One is directfrom Inline molders while second is offline feeding through buffer location. So Offline loading of disc frombuffer is synchronized with Inline molder’s feeding through a software and plays a vital role in cycle time. IfDisc loading from buffer stops or decreased, then cycle time shoots up. It is measured in number of discloaded.Input Molder /precoolerBufferL0CoolingConveyorDisc Loading from BufferDisc from Inline molders
  31. 31. OPERATIONAL DEFINITION ( X3 & X4 )DYE PROCESSING TIME: It is the time taken by dye coater section to convert a single blank active substrateinto dye coated disc with specified qualities and characteristics. It includes APPLY DYE Time and DYESPINNING Time. Both times run simultaneously.DYE CONVEYOR STEPPING TIME: It is the time taken by Dye conveyor to step pin carrying disc in front of onedye cup to the location in front of next dye cup. It is measured in seconds by stopwatch .DYE CUPSPOSITION A POSITION BAs shown in diagram, Dye conveyor Stepping Time is thetime taken to move from position A to Position B by the pincarrying blank/Dye coated active disc.DYE CONVEYOR
  32. 32. OPERATIONAL DEFINITION ( X5 )DRYER WAITING TIME: Dryer In CH-II works in two steps. During First Step its Left (L) and Right(R) Suckerspick dye coated disc from dye conveyor. And then it waits for certain time interval for the third dye coated discthen second step is dryer I/P arm again moves down to pick that Third disc by Middle (M) sucker. This waitingtime of dryer for third disc during its second step is called Dryer waiting Time. It is measured in seconds bystop watch.Time for dryer for which dryer handler waits for the disc-1 to come under sucker Middle (M) while disc-2 anddisc-3 were carried by L and R sucker respectively iscalled dryer waiting time.
  33. 33. OPERATIONAL DEFINITION ( X6 / X7 / X8 )SPUTTERING TIME: Time taken by metallizer to sputter the silver (or any other reflective material) onto the discof desired thickness (in nm). It is measured in seconds and displayed on metallizer screen.BONDING PROCESSING TIME: Time taken by the finish disc to undergo the complete bonding process.Bonding process consist of three main process :1.Resin application time : During this time bonding resin is applied between Active and Dummy Disc.2. Vacuum Capillary Action Time. Resin moves towards moat area under the influence of vacuum.3.Spinning process Time: Spinning time during which extra resin is spin off from disc.All three aforesaid times are measured in msec and displayed on machine profile.DISC SCANNING TIME: It is the time taken by final scanner to scan the finished DVD-R disc for various Global,Top side and bottom side defects. It is directly proportional to sensitivity of scanner and number of defects ondisc. It is measured in msec and displayed on final scanner screen
  34. 34. NORMALITY TEST - Y1 CoolingConveyorCooling ConveyorPercent2.152.102.052.001.951.9099.99995908070605040302010510.1Mean<0.0052StDev 0.04235N 90AD 2.082P-ValueNor malit y t est - cooling ConveyorNormalConclusion : Data is not normal as P valve < 0.05
  35. 35. GRAPHICAL - SUMMARY - Y1Conclusion : Data is not normal as P valve < 0.052.082.042.001.961.92MedianMean2.0102.0052.0001.9951.9901st Quartile 1.9700Median 1.99003rd Quartile 2.0300Maximum 2.10001.9911 2.00891.9900 2.00000.0369 0.0496A-Squared 2.08P-V alue < 0.005Mean 2.0000StDev 0.0423Variance 0.0018Skew ness 0.342293Kurtosis 0.408117N 90Minimum 1.9000Anderson-Darling Normality Test95% Confidence I nterv al for Mean95% Confidence I nterv al for Median95% Confidence I nterv al for StDev9 5 % Conf idence I nt er v alsGr aphical Summer y f or Cooling Conveyor
  36. 36. Conclusion : Data is stable as all points are within the control limits of both Individualand Moving range chartsI – MR CHART Y1
  37. 37. NORMALITY TEST - Y2 Dye CoaterConclusion : Data is not normal as P valve < 0.05
  38. 38. 2.202.162.122.082.042.00MedianMean2.092.082.072.062.052.041st Quartile 2.0300Median 2.05003rd Q uartile 2.1100Maximum 2.23002.0597 2.08232.0400 2.08760.0470 0.0632A-Squared 3.07P-Value < 0.005Mean 2.0710StDev 0.0539Variance 0.0029Skew ness 0.846120Kurtosis -0.030582N 90Minimum 2.0000Anderson-Darling Normality Test95% Confidence I nterv al for Mean95% Confidence I nterv al for Median95% Confidence I nterv al for StDev9 5 % Conf idence I nt er v alsGr aphical Summar y f or Dye coaterGRAPHICAL - SUMMARY - Y2Conclusion : Data is not normal as P valve < 0.05
  39. 39. I – MR CHART Y2Conclusion : Data is not stable as all points are within the control limits of Individualrange but few data points out of Moving range charts
  40. 40. Conclusion : Data is not normal as P valve < 0.05NORMALITY TEST - Y3 Dryer
  41. 41. 2.202.162.122.082.042.00MedianMean2.092.082.072.062.052.041st Quartile 2.0275Median 2.05003rd Quartile 2.1100Maximum 2.23002.0577 2.08142.0400 2.09000.0492 0.0662A-Squared 2.81P-Value < 0.005Mean 2.0696StDev 0.0564Variance 0.0032Skew ness 0.756471Kurtosis -0.261359N 90Minimum 2.0000Anderson-Darling Normality Test95% Confidence I nterv al for Mean95% Confidence I nterv al for Median95% Confidence I nterv al for StDev9 5 % Co nf i de nce I nt er v a lsGr aphi cal Summar y f or Dr yerConclusion : Data is not normal as P valve < 0.05GRAPHICAL - SUMMARY - Y3
  42. 42. I – MR CHART Y3Conclusion : Data is not stable as all points are within the control limits of Individualrange but few data points out of Moving range charts
  43. 43. NORMALITY TEST - Y4 MetallizerMet allizerPercent2.252.202.152.102.052.001.951.9099.99995908070605040302010510.1Mean<0.0052.068StDev 0.05146N 90AD 2.983P-ValueNor mality test - MetallizerNormalConclusion : Data is not normal as P valve < 0.05
  44. 44. GRAPHICAL - SUMMARY - Y42.162.122.082.042.00MedianMean2.082.072.062.052.041st Quartile 2.0300Median 2.05003rd Quartile 2.1100Maximum 2.19002.0571 2.07872.0400 2.08000.0449 0.0603A-Squared 2.98P-Value < 0.005Mean 2.0679StDev 0.0515Variance 0.0026Skew ness 0.679820Kurtosis -0.491292N 90Minimum 2.0000Anderson-Darling Normality Test95% Confidence I nterv al for Mean95% Confidence I nterv al for Median95% Confidence I nterv al for StDev9 5 % Co nf idence I nt e r v a lsGr aphi cal Summar y f or Met al li zerConclusion : Data is not normal as P valve < 0.05
  45. 45. I – MR CHART Y4Conclusion : Data is stable as all points are within the control limits of both Individualand Moving range charts
  46. 46. NORMALITY TEST - Y5 BondingConclusion : Data is not normal as P valve < 0.05
  47. 47. GRAPHICAL - SUMMARY - Y52.202.162.122.082.042.00MedianMean2.092.082.072.062.052.041st Quartile 2.0300Median 2.05003rd Quartile 2.1100Maximum 2.23002.0603 2.08502.0400 2.09000.0514 0.0691A-Squared 3.00P-Value < 0.005Mean 2.0727StDev 0.0589Variance 0.0035Skew ness 0.678084Kurtosis -0.571859N 90Minimum 2.0000Anderson-Darling Normality Test95% Confidence I nterv al for Mean95% Confidence I nterv al for Median95% Confidence I nterv al for StDev9 5 % Conf idence I nt er v alsGr aphical Summar y f or BondingConclusion : Data is not normal as P valve < 0.05
  48. 48. I – MR CHART Y5Conclusion : Data is stable as all points are within the control limits of both Individualand Moving range charts
  49. 49. NORMALITY TEST - Y6 Final scannerConclusion : Data is not normal as P valve < 0.05
  50. 50. GRAPHICAL - SUMMARY - Y6Conclusion : Data is not normal as P valve < 0.052.162.122.082.042.001.96MedianMean2.0402.0352.0302.0252.0202.0152.0101st Quartile 2.0000Median 2.01003rd Quartile 2.0500Maximum 2.16002.0177 2.03742.0100 2.03000.0409 0.0549A-Squared 2.95P-V alue < 0.005Mean 2.0276StDev 0.0469Variance 0.0022Skew ness 0.91807Kurtosis 1.38411N 90Minimum 1.9400Anderson-Darling Normality Test95% Confidence I nterv al for Mean95% Confidence I nterv al for Median95% Confidence I nterv al for StDev9 5 % Con f ide nce I nt er v al sGr aphical Summar y f or Final Scanner
  51. 51. I – MR CHART Y6Conclusion : Data is unstable as some point are out of control limit in both Individualand Moving range charts .
  52. 52. BASE LINE DATA ( Y’s )YSAMPLESIZEMEAN MEDIAN STD DEV NORMALITYP VALUEofNormalitySTABILITY CP / CPKY1CoolingConveyor90 2.0 1.99 0.0423 No < 0.005 Yes NAY2DyeCoater90 2.07 2.05 0.0539No < 0.005 NAY3Dryer90 2.069 2.05 0.056No < 0.005 NAY4Metallizer90 2.068 2.05 0.0515No < 0.005 NAY5Bonding90 2.07 2.05 0.0589No < 0.005 Yes NAY6FinalScanner90 2.027 2.01 0.047No < 0.005 NA
  53. 53. DATA MEASUREMENT PLAN ( X’s )Performance measure(X’s)Operational definitionData sourceand locationSamplesizeWho willcollect thedataWhen willdata becollectedHow will data becollectedX1 Stepping Time ofCooling ConveyorAs defined inoperationaldefinitionStop Watch 60 Ruchir 28thSept’11 20readings/shift/dayX2 Disc Loading fromBufferCount manually 60 Piyush 28thSept’11 20readings/shift/dayX3 Dye Processing TimeDye coaterscreen60 Sharad 28thSept’11 20readings/shift/dayX4 Dye ConveyorStepping TimeStop Watch 60 Ruchir 28thSept’11 20readings/shift/dayX5 Dryer waiting Time Stop Watch 60 Piyush 28thSept’11 20readings/shift/dayX6 Sputtering TimeMetallizerScreen60 Piyush 28thSept’11 20readings/shift/dayX7 Bonding ProcessingTimeBonding- LineMain screen60 Piyush 28thSept’11 20readings/shift/dayX8 Disc Scanning TimeFinal scannerscreen60 Ruchir 28thSept’11 20readings/shift/day
  54. 54. 2.102.052.001.951.90MedianMean2.0052.0001.9951.9901.9851.9801st Quartile 1.9600Median 1.99003rd Quartile 2.0150Maximum 2.10001.9782 2.00361.9900 2.00000.0350 0.0534A-Squared 0.78P-Value 0.040Mean 1.9909StDev 0.0423Variance 0.0018Skew ness 0.154610Kurtosis 0.152815N 45Minimum 1.9000Anderson-Darling Normality Test95% Confidence I nterv al for Mean95% Confidence I nterv al for Median95% Confidence I nterv al for StDev9 5 % Conf idence I nt er v alsGr aphical Summar y f or St epping time Cooling ConveyorGRAPHICAL - SUMMARY X1Conclusion : Data is normal as P valve > 0.05.
  55. 55. 4541373329252117139512.102.052.001.951.90Obser v at ionIndividualValue_X= 1.9909UCL= 2.0810LCL= 1.90084541373329252117139510.1000.0750.0500.0250.000Obser v at ionMovingRange__MR= 0.0339UCL= 0.1106LCL= 066161I MR char t of stapping t ime cooling conveyorI – MR CHART X1Conclusion : Data is unstable in certain point out of control limits of Individual range chartsand 4 point > 1 standard deviation from the center line.
  56. 56. GRAPHICAL - SUMMARY X21098MedianMean9.08.98.88.78.61st Quartile 8.0000Median 9.00003rd Quartile 9.0000Maximum 10.00008.6122 8.98789.0000 9.00000.5176 0.7898A-Squared 4.84P-Value < 0.005Mean 8.8000StDev 0.6252Variance 0.3909Skew ness 0.163488Kurtosis -0.463876N 45Minimum 8.0000Anderson-Darling Normality Test95% Confidence I nterv al for Mean95% Confidence I nterv al for Median95% Confidence I nterv al for StDev9 5 % Conf idence I nt er v alsSummar y for Disc loading fr om BufferConclusion : Data is not normal as P valve < 0.05 and Johnson / Box-Coxtransformation is not making data normal
  57. 57. I – MR CHART X2Conclusion : Data is stable as all points are within the control limits of both Individualand Moving range charts but 7point in a row same side from center line and somepoint >2&1 standard deviation.
  58. 58. GRAPHICAL - SUMMARY X3940093809360934093209300MedianMean9400938093609340932093001st Quartile 9300.0Median 9350.03rd Quartile 9400.0Maximum 9400.09334.2 9361.39300.0 9400.037.4 57.1A-Squared 4.71P-Value < 0.005Mean 9347.8StDev 45.2Variance 2040.4Skew ness 0.09007Kurtosis -1.80536N 45Minimum 9300.0Anderson-Darling Normality Test95% Confidence I nterv al for Mean95% Confidence I nterv al for Median95% Confidence I nterv al for StDev9 5 % Conf iden ce I n t er v alsSummar y f or Dye Pr ocessing Time( msec)Conclusion : Data is not normal as P valve < 0.05 and Johnson / Box-Coxtransformation is not making data normal
  59. 59. I – MR CHART X3Conclusion : Data is stable as all points are within the control limits of both Individualand Moving range charts45413733292521171395194509400935093009250O bser v at ionIndividualValue_X= 9347.8UCL= 9474.7LCL= 9220.845413733292521171395116012080400O bser v at ionMovingRange__MR= 47.7UCL= 155.9LCL= 06666I MR char t of dye pr ocessing t ime
  60. 60. GRAPHICAL - SUMMARY X42.162.122.082.042.00MedianMean2.092.082.072.062.052.041st Q uartile 2.0300Median 2.05003rd Quartile 2.1100Maximum 2.19002.0523 2.08412.0400 2.09000.0437 0.0667A -Squared 1.38P-V alue < 0.005Mean 2.0682StDev 0.0528V ariance 0.0028Skew ness 0.734993Kurtosis -0.343090N 45Minimum 2.0000Anderson-Darling Normality Test95% Confidence I nterv al for Mean95% Confidence I nterv al for Median95% Confidence I nterv al for StDev9 5 % Co nf id en ce I n t er v a lsSummar y f or Dye conveyor st eppi ng t imeConclusion : Data is not normal as P valve < 0.05.
  61. 61. I – MR CHART X44541373329252117139512.22.12.01.9O bser v a t ionIndividualValue_X= 2.0682UCL= 2.2109LCL= 1.92564541373329252117139510.200.150.100.050.00O bser v a t ionMovingRange__MR= 0.0536UCL= 0.1752LCL= 011I MR char t of dye conveyor st apping t imeConclusion : Data is Unstable as certain points are outside the control limits in Movingrange chart.
  62. 62. GRAPHICAL - SUMMARY X54.003.923.843.763.68MedianMean3.903.893.883.873.863.853.841st Quartile 3.8100Median 3.88003rd Quartile 3.9600Maximum 3.99003.8405 3.89823.8700 3.88000.0795 0.1213A-Squared 1.83P-Value < 0.005Mean 3.8693StDev 0.0960Variance 0.0092Skew ness -0.755555Kurtosis -0.101855N 45Minimum 3.6700Anderson-Darling Normality Test95% Confidence I nterv al for Mean95% Confidence I nterv al for Median95% Confidence I nterv al for StDev9 5 % Conf idence I nt er v alsSummary for Dryer Waiting TimeConclusion : Data is not normal as P valve < 0.05.
  63. 63. I – MR CHART X54541373329252117139514.204.053.903.753.60Obser v at ionIndividualValue_X= 3.8693UCL= 4.1413LCL= 3.59734541373329252117139510.30.20.10.0Obser v at ionMovingRange__MR= 0.1023UCL= 0.3342LCL= 0I MR char t of dr yer w aiting timeConclusion : Data is stable as all points are within the control limits of both Individualand Moving range charts
  64. 64. GRAPHICAL - SUMMARY X6Conclusion : Data is not normal as all the data are identical.
  65. 65. GRAPHICAL - SUMMARY X72.102.082.062.042.022.00MedianMean2.0702.0652.0602.0552.0502.0452.0401st Quartile 2.0100Median 2.05003rd Quartile 2.0900Maximum 2.11002.0416 2.06422.0400 2.07000.0312 0.0475A-Squared 1.12P-Value 0.005Mean 2.0529StDev 0.0376Variance 0.0014Skew ness 0.16854Kurtosis -1.28583N 45Minimum 2.0000Anderson-Darling Normality Test95% Confidence I nterv al for Mean95% Confidence I nterv al for Median95% Confidence I nterv al for StDev9 5 % Conf idence I nt er v alsSummar y f or Bonding Pr ocessing TimeConclusion : Data is not normal as P valve < 0.05.
  66. 66. I – MR CHART X74541373329252117139512.152.102.052.001.95Obse r v at ionIndividualValue_X= 2.0529UCL= 2.1472LCL= 1.95864541373329252117139510.1000.0750.0500.0250.000Obse r v at ionMovingRange__MR= 0.0355UCL= 0.1158LCL= 066I MR char t of bonding pr ocessing timeConclusion : Data is stable as all points are within the control limits of both Individualand Moving range charts but 2 points > 2 standard deviation from the center line.
  67. 67. GRAPHICAL - SUMMARY X814881472145614401424MedianMean1465.01462.51460.01457.51455.01452.51450.01st Quartile 1450.0Median 1459.03rd Quartile 1466.0Maximum 1490.01451.5 1460.61452.0 1466.012.6 19.2A-Squared 1.85P-Value < 0.005Mean 1456.0StDev 15.2Variance 231.5Skew ness -0.302294Kurtosis 0.250692N 45Minimum 1427.0Anderson-Darling Normality Test95% Confidence I nterv al for Mean95% Confidence I nterv al for Median95% Confidence I nterv al for StDev9 5 % Con f ide nce I nt er v alsSummar y f or Di sc Scanning Time ( msec)Conclusion : Data is not normal as P valve < 0.05.
  68. 68. I – MR CHART X845413733292521171395115001480146014401420Obser v at io nIndividualValue_X= 1456.04UCL= 1498.30LCL= 1413.79454137332925211713951483624120Obser v at io nMovingRange__MR= 15.89UCL= 51.91LCL= 0I MR char t of dye scanning t imeConclusion : Data is stable as all points are within the control limits of both Individualand Moving range charts.
  69. 69. BASE LINE DATA ( X’s )XSAMPLESIZEMEAN MEDIAN STD DEV NORMALITYP VALUE ofNormalitySTABILITY CPX1 Stepping Time ofCooling Conveyor60 1.99 1.99 0.0423 NO 0.04 NO NAX2 Disc Loadingfrom Buffer60 8.8 9 0.6252 NO <0.005 YES NAX3 Dye ProcessingTime60 9347.8 9350 45.2 NO <0.005 YES NAX4 Dye ConveyorStepping Time60 2.068 2.05 0.0528 NO <0.005 NO NAX5 Dryer waitingTime60 3.87 3.88 0.096 NO <0.005 YES NAX6 Sputtering Time 60DATA WAS IDENTICAL IN ALL READINGS – 1.4 SECSHOWS AN ERROR IN GRAPHICAL SUMMARYX7 BondingProcessing Time60 2.055 2.05 0.038 NO <0.005 YES NAX8 Disc ScanningTime60 1456 1459 15.2 NO <0.005 YES NA
  70. 70. mANALYZEAnalyze
  71. 71. AnalyzeS.No XPRIORITIZED X’s from CE-MatrixValidated(Y/N)Tools Used1 X1Stepping Time of CoolingConveyorY Mann whitney2 X2 Disc Loading from Buffer Y Mann whitney3 X3 Dye processing Time Y FMEA4 X4 Dye Conveyor setting Time Y Mann whitney5 X5 Dryer waiting Time Y Mann whitney6 X6 Sputtering Time Y Mann whitney7 X7 Bonding processing Time Y Mann whitney8 X8 Disc Scanning Time Y Gage R&R
  72. 72. Validation of Stepping Time of cooling conveyor(X1)Ho: Stepping time of Cooling conveyor with modified gear design =Stepping Time of coolingconveyor with Normal gear designHa: Stepping time of Cooling conveyor with modified gear design < Stepping Time of coolingconveyor with Normal gear designMann-Whitney Test and CI: NORMAL GEAR, MODIFIED GEARN MedianNORMAL GEAR 45 1.9900MODIFIED GEAR 45 1.8300Point estimate for ETA1-ETA2 is 0.170095.0 Percent CI for ETA1-ETA2 is (0.1500,0.1800)W = 3060.0Test of ETA1 = ETA2 vs ETA1 not = ETA2 is significant at 0.0000The test is significant at 0.0000 (adjusted for ties)Here ‘significant’ value <0.05 So we reject Null Hypothesis.Stepping time of Cooling conveyor with modified gear design < Stepping Time of cooling conveyorwith Normal gear designAnalyze
  73. 73. Box plot for Validation – X1AnalyzeConclusion : Stepping time with Modified gear Box is less than Normal gear Box
  74. 74. AnalyzeModification - Cooling Conveyor
  75. 75. Validation of Disc Loading from Buffer (X2)AnalyzeHo: Number of Disc Loading from buffer per minute with new software = Number of Disc Loading frombuffer per minute (Before)Ha: Number of Disc Loading from buffer per minute with new software > Number of Disc Loading frombuffer per minute (Before)Mann-Whitney Test and CI: Buffer loading (OLD Software) vs Buffer loading (NEWSoftware)N MedianBuffer loading (OLD Software) 45 9.000Buffer loading (NEW Software) 45 12.000Point estimate for ETA1-ETA2 is -3.00095.0 Percent CI for ETA1-ETA2 is (-3.000,-3.000)W = 1035.0Test of ETA1 = ETA2 vs ETA1 not = ETA2 is significant at 0.0000The test is significant at 0.0000 (adjusted for ties)Here ‘Significant’ value <0.05 So we reject Null Hypothesis.Conclusion : Number of Disc Loading per minute from buffer with new software > Number of DiscLoading per minute from buffer (Before)
  76. 76. AnalyzeBox plot for Validation – X2DataBuffer loading- BeforeBuffer Loading with new softwar1312111098Boxplot of Buffer Loading w ith new softw ar, Buffer loading- BeforeConclusion : Disc loading from buffer with new software is more as compared to the Normal discloading condition from buffer ( Before)
  77. 77. AnalyzeBuffer LoadingWithModification insoftware logic inPLC, Buffer willload discaccording to thedelay timer andirrespective ofdisc presence onprecooler pins.Earlier it placesdisc if any one ofP-1 or P-7 pinwas empty
  78. 78. AnalyzeBuffer Loading- modification done in FB1740
  79. 79. AnalyzeFMEA - Dye Processing Time (X3)Process / product Dye processing time FMEA Date (Original)FMEA Team Piyush (Revised)Black belt / Green belt Black Belt Page: 1 Of 1Process Actions ResultsProcesssteps/requirementsPotentialfailuremodePotentialeffectsoffailureSeverityPotentialcause(s)offailureOccurrenceCurrentcontrolsDetectionRiskprioritynumberRecommendedactionResponsibilityandtargetcompletiondateActiontakenSeverityOccurrenceDetectionRiskprioritynumberText Text Text Number Text Number Text Number calculationText Text Text Number Number Number CalculationDyeprocessing timeLow /HighOpticalDensityElectricalErrors inDisc 4Spinningprofile3OnlineODdetection 1 12ModifiedDyeProfilewith HighDyeconcentrationwithsameopticalRuchir /SharadTR hasbeenpublished andDocumentedthroughTQM4 2 1 8PoorgrooveFillingElectricalErrors4Spinningprofile3ShiftbasisD(abs)checking3 36 4 2 2 16Improper Rejection Profile 100%
  80. 80. AnalyzeValidation of Dye Processing Time (X3)Ho: Dye processing time with modified profile = Dye processing time with original profileHa: Dye processing time with modified profile < Dye processing time with original profileMann-Whitney Test and CI: Dye Processing Time(msec) Befor vs Dye ProcessingTime(msec)AfterN MedianDye Processing Time(msec) 45 9350.0Dye Processing Time(msec)- Afte 45 7900.0Point estimate for ETA1-ETA2 is 1400.095.0 Percent CI for ETA1-ETA2 is (1400.0,1400.0)W = 3060.0Test of ETA1 = ETA2 vs ETA1 not = ETA2 is significant at 0.0000The test is significant at 0.0000 (adjusted for ties)Here ‘Significant’ value <0.05 So we reject Null Hypothesis and accept AlternateHypothesisConclusion : Dye processing time with modified profile is less than processing time oforiginal profile
  81. 81. AnalyzeBox plot for Validation – X3Dataoriginal profileModified profile94009200900088008600840082008000Boxplot of Dye processing time Modified profile Dye Vs original Dye profileConclusion : Dye processing time (X3) is low with modified dye profile as compared to originalprofile
  82. 82. AnalyzeValidation of Dye Conveyor Stepping Time (X4)Ho: Stepping time of Dye conveyor with modified gear design =Stepping Time of Dye conveyor withNormal gear designHa: Stepping time of Dye conveyor with modified gear design < Stepping Time of Dye conveyorwith Normal gear designMann-Whitney Test and CI: Stepping time (Normal Gear) vs Stepping time(Modified Gear)N MedianStepping time (Normal Gear) 45 2.0500Stepping time (Modified Gear) 45 1.8000Point estimate for ETA1-ETA2 is 0.260095.0 Percent CI for ETA1-ETA2 is (0.2400,0.2800)W = 3060.0Test of ETA1 = ETA2 vs ETA1 not = ETA2 is significant at 0.0000The test is significant at 0.0000 (adjusted for ties)Here ‘significant’ value <0.05 So we reject Null Hypothesis and accept Alternate HypothesisConclusion : Stepping Time of dye conveyor with modified gear design is lower than normal gear
  83. 83. AnalyzeBox plot for Validation – X4Conclusion : Stepping Time with modified gear design in dye conveyor (X4) is less ascompared to normal gearDataStepping Time - Normal GearStepping Time - Modified Gear2.22.12.01.91.8Boxplot of Dye conveyor Stepping Time
  84. 84. AnalyzeModification - Dye Conveyor Stepping Time1 Drive motor with gear 2 Belt-tensionlightener3 Conveyor 4 Conveyor pinNormal Gear Design Modified Gear DesignNo of teeth = 25 No of teeth = 20Gear Box Side Pulley Motor Side Pulley Motor Side PulleyNo of teeth = 20 No of teeth = 25Gear Box Side Pulley
  85. 85. AnalyzeValidation of Dryer waiting Time (X5)Ho: Dryer waiting Time with two stacks ( AFTER software Modification) =Dryer Waiting Timewith three stacks ( NORMAL condition)Ha:Dryer waiting Time with two stacks ( AFTER software Modification) < Dryer WaitingTime with three stacks ( NORMAL condition)Here ‘significant’ value <0.05 So we reject Null Hypothesis and accept Alternate HypothesisConclusion : Dryer waiting Time with two stacks (AFTER software modification) is low as toNORMAL conditionMann-Whitney Test and CI: Dryer Waiting Time-Normal vs Dryer Waiting Time-ModifiedN MedianDryer Waiting Time-Normal 45 3.8800Dryer Waiting Time-Modified 45 1.1800Point estimate for ETA1-ETA2 is 2.700095.0 Percent CI for ETA1-ETA2 is (2.6900,2.7200)W = 3060.0Test of ETA1 = ETA2 vs ETA1 not = ETA2 is significant at 0.0000The test is significant at 0.0000 (adjusted for ties)
  86. 86. AnalyzeBox plot for Validation – X5DataDryer Waiting Time-NORMALDryer Waiting Time-AFTER4.03.53.02.52.01.51.0Boxplot of Dryer Waiting TimeConclusion : Dryer waiting Time with two stacks (AFTER software modification)is low as to NORMAL condition
  87. 87. AnalyzeDRYER L0 MODIFICATIONDryer with THREE stacks -NORMAL Dryer Modification with TWO stacks -AFTEREarlier dryer I/P handler picks two disc in L/R sucker and waits for sec forthe third disc. We made a modification in functional block-FB 1722 in PLClogic so that dryer will pick only two disc and doesn’t wait for third disc.When third disc came, dryer handler comes back for the next operation.
  88. 88. AnalyzeValidation of Sputtering Time (X6)Ho: Metallizer Cycle Time with Sputter Time (ST) 1.1 sec =Metallizer Cycle Time with SputterTime (ST) 1.4 secHa: Metallizer Cycle Time with Sputter Time (ST) 1.1 sec < Metallizer Cycle Time with Sputter Time(ST) 1.4 sec (ST) 1.4 secHere ‘p’ value <0.05 So we reject Null Hypothesis and accept Alternate HypothesisConclusion : Metallizer Cycle Time with sputter time 1.1sec is less than in comparison withsputter time 1.4secMann-Whitney Test and CI: Sputter Time- Normal vs Sputter Time-ModifiedN MedianSputter Time- Normal 45 1.4000Sputter Time-Modified 45 1.1000Point estimate for ETA1-ETA2 is 0.300095.0 Percent CI for ETA1-ETA2 is (0.3000,0.3000)W = 3060.0Test of ETA1 = ETA2 vs ETA1 not = ETA2 is significant at 0.0000The test is significant at 0.0000 (adjusted for ties)
  89. 89. AnalyzeBox plot for Validation – X6DataMetallizer with ST 1.4Metallizer with ST 1.12.22.12.01.91.8Boxplot of Metallizer Cycle Time with Sputter Time (ST) 1.4 sec and 1.1 secConclusion : Metallizer Cycle Time with sputter time 1.1sec is less than in comparisonwith sputter time 1.4sec
  90. 90. AnalyzeValidation of Bonding Processing Time (X7)Ho: Bonding processing time with modified profile = Bonding processing time with Normal profileHa: Bonding processing time with modified profile < Bonding processing time with Normal profileBonding processing time with Normal profileMann-Whitney Test and CI: Normal bonding profile vs Modified bonding profileN MedianNormal bonding profile 45 2.0500Modified bonding profile 45 1.8200Point estimate for ETA1-ETA2 is 0.230095.0 Percent CI for ETA1-ETA2 is (0.2200,0.2400)W = 3060.0Test of ETA1 = ETA2 vs ETA1 not = ETA2 is significant at 0.0000The test is significant at 0.0000 (adjusted for ties)Here ‘significant’ value <0.05 So we reject Null Hypothesis and accept Alternate HypothesisConclusion : Bonding processing time with modified profile is less than processing time withNormal profile
  91. 91. AnalyzeBox plot for Validation – X7DataNormal Bonding profileModified Bonding profile2.22.12.01.91.8Boxplot of Bonding profile comparisonConclusion : Bonding Processing Time with Modified Profile is less as compared toNormal Profile
  92. 92. AnalyzeValidation of Disc Scanning Time (X8)Ho: Disc Scanning time After = Disc Scanning time beforeHa: Disc Scanning time After < Disc Scanning time before isc Scanning timebeforeMann-Whitney Test and CI: Scanning Time-Before Vs Scanning Time -AfterN MedianScanning Time-Before 45 1459.0Scanning Time -After 45 1055.0Point estimate for ETA1-ETA2 is 399.095.0 Percent CI for ETA1-ETA2 is (389.0,412.0)W = 3060.0Test of ETA1 = ETA2 vs ETA1 not = ETA2 is significant at 0.0000The test is significant at 0.0000 (adjusted for ties)Here ‘p’ value <0.05 So we reject Null Hypothesis and accept Alternate HypothesisConclusion : Disc Scanning time After implementing new software is less as compared to the BEFORE
  93. 93. AnalyzeBOX PLOT- X8DataScanning time - beforeScanning Time - After150014001300120011001000Boxplot of Disc Scanning Time - comparisonConclusion : Disc Scanning time After implementing new software is less as compared to theBEFORE
  94. 94. AnalyzeGage - run chart for defect comparison in scannerscannerdefectsizeMean600400200600400200Mean1 2 3 4 56 7 8 9 10scannerModificationNormalGage name: Defect Size comparison in Normal and Modified scannDate of study :Reported by :Tolerance:Misc:Panel variable: discGage Run Chart of defect size by disc at different scanner set t ings
  95. 95. AnalyzeGage R&R for defect size comparisonPercentPart-to-PartReprodRepeatGage R&R100500% Contribution% Study VarSampleRange1050_R= 3.05UCL= 6.45LCL= 0Modification NormalSampleMean600400200__X= 377.0UCL= 378.8LCL= 375.3Modification NormalscannerdiscNormalModification1098765432110987654321600400200scannerNormalModification600400200Com ponent s of Var iat ionR Char t by scannerXbar Char t by scannerdef ect size By disc ( scanner )def ect size by scannerGage R& R (Nest ed) for defect size
  96. 96. Improve
  97. 97. List of Possible SolutionsS.No Y y SolutionsTool used forValidationDriver Side pulley Changed from 16 teeth to 25 teeth Hypothesis TestingSoftware modification done in FB1740, network 22 of PLCprogramHypothesis TestingModified Dye processing profile with lower dye processing time<8400 msec loaded in lineFMEA / HypothesisTestingDriver side/ Driven side pullies changed to 25 / 20 from20 / 25Hypothesis Testing3 DryerSoftware modified for two stack operation by chnaging programin FB 1722, network 96,97Hypothesis Testing4 Metallizer Sputtering time reduced to 1.1sec from 1.4 sec Hypothesis Testing5 BondingModified Bonding profile with lower processing time(<1300msec each spinner )is implemented in line.Hypothesis Testing6 Final Scanner Modified Software with fast scanning is implement in lineGage R & R /Hypothesis Testing2 Dye CoaterDye Processing timeDye Conveyor SteppingTimeDryer waiting TimeSputtering TimeBonding processing TimeDisc scanning TimeXs Validated1CYCLETIME-CHALLENGER-IICooling ConveyorStepping timeDisc loading from Buffer
  98. 98. TASK ACTIVITIES RESPONSIBILITY START DATE DUE DATE STATUS & ACTIONDriver Side pulley to be change from 16 teethto 25 teethSharad / NS Rao 16-Nov11 17-Nov11 compleletedModified Software of buffer loading to be loadin lineNS Rao / Shailender 17-Nov11 17-Nov11 compleletedModified Dye processing profile with higherDye Concentration (1.4) to be load in lineRuchir / Aditya 17-Nov11 17-Nov11 compleletedDriver side and Driven side pullies to bechanged to 25 / 20 from 20 / 25Sharad / NS Rao 16-Nov11 17-Nov11 compleletedModified software with two stacks loading willbe implemented in lineShailender 18-Nov11 18-Nov completedSputtering time to be reduced to 1.1sec from1.4 secRuchir 17-Nov11 17-Nov11 completedModified Bonding profile with lowerprocessing time to be implement in lineSharad / NS Rao 17-Nov11 18-Nov11 completedModified Software with fast scanning to beimplement in lineNS Rao / Ruchir 17-Nov 17-Nov11 completedDVD-R quality Datacollection and anaylsisData Collection and anakysis of critical QualityparametersRuchir / Anuj / Aditya 19-Nov11 29-Nov completedStatistical Analysis andFinal ConclusionStatistical Analysis of line during pilot run forlower Cycle timeRuchir / Sharad 19-Nov11 29-Nov11 completedImplementation of all thepossible solutions in linePilot Implementation planning
  99. 99. Pilot Plan - Result
  100. 100. BASE LINE DATA (Y’s) - ImprovementYSAMPLESIZEMEAN MEDIAN STD DEV NORMALITYP VALUEofNormalitySTABILITY CP / CPKY1CoolingConveyor90 1.84 1.84 0.109 No <0.005 Yes NAY2DyeCoater90 1.842 1.84 0.10No<0.005 YesNAY3Dryer90 1.82 1.82 0.006No<0.005 YesNAY4Metallizer90 1.846 1.85 0.01No<0.005 NoNAY5Bonding90 1.83 1.84 0.01No<0.005 YesNAY6FinalScanner90 1.835 1.83 0.012No<0.005 NoNA
  101. 101. Impact of Cycle time reduction on Important Disc Quality Parameters•Key parameters identified are –1- Electrical – DC Jitter, Pisum8 , R14h•DC Jitter:- It is the random variation in Pit & Land lengths compared from systemclock.Specification<= 10.25•R14h :- Reflectivity is measured as % of incident light beam reflected from thedisc surface.Specification>= 42.5%•PISUM8:- It is the sum of Parity inner error(PIE) in running window of consecutive8-ECC blocks.Specification<=200 errors2- Mechanical –TE / FE•TE :- Tracking Error indicates how well the pick up can follow the spiral tracksof the disc.Specification<=60•FE :- Focusing Error indicates how well the pick up can follow the laser beam onthe disc surface.Specification<=35
  102. 102. 3.WRS( Write/Read status ) test – Advance Media Lab Report• WRS :- This test is performed to check the disc compatibility withdifferent drives for writing speed / reading speed and errors related with it.
  103. 103. Box Plot of Electrical ParametersValuesAft er Revert BackDur ing TrialBefor e Trial13121110987Boxplot of DC Jit ter ( MAX)DataAfter Revert BackDuring TrialBefore Trial4948474645444342 42Boxplot of R14h (Min)During Trial run, testing writer was changed, causing a slight offset, so data was compared withthe revert back condition.For PISUM8 Drive compatibility test was done on 10 different drives.(data attached)
  104. 104. Drive compatibility needs to be improve in all drives. So samples werechecked by IPQC in 10 specific drive for compatibility test
  105. 105. Drive compatibility data – 10 drivesBENQ 1670 A 16 11.94 16.01 6.08 OK 122 1PIO 111 B 16 9.1 8 7.25 OK 1661 1LIT-165 C 16 11.92 15.94 7.34 ER 1664 1NEC 4550 D 16 11.75 16.05 6.12 OK 176 0PANASONIC F 8 5.87 6 10.17 OK 36 0OPTIARC H 16 11.83 15.99 5.55 OK 136 0LIT-DH20 J 16 12.08 16.12 5.52 OK 1462 1PIO 215 K 16 11.73 16.08 6.04 OK 1656 1LG H55 I 16 11.9 16.07 5.46 OK 1048 1BENQ 1670 A 16 11.94 15.9 6.12 OK 410 1PIO 111 B 16 11.25 12.51 6.13 OK 875 1LIT-165 C 16 11.84 15.91 6.38 ER 1664 1NEC 4550 D 16 11.67 15.95 6.27 OK 129 0PANASONIC F 8 3.93 4 15.14 OK 68 0OPTIARC H 16 11.72 15.98 6.09 OK 120 0LIT-DH20 J 16 12.06 16.13 5.53 OK 244 0PIO 215 K 18 11.67 16.08 5.52 OK 278 0LG H55 I 16 11.89 16.08 5.47 OK 754 0448 +R 2.1Above Data shows that drive compatibilty is poor in LIT-DH20 and PIO 215 DrivesREADBACKPI Sum 8Max<=280POF=0434 +R 1.85Line running with Lower Cycle time ( L-434) is compared with Line running with normal Cycle Time (L-448) for DRIVECOMPATIBILITYLine No MediaCYCLETIMEWriter NameWriterCodeSENSINGSPEEDAVERAGESPEEDENDSPEED>=15.49ElapsedTimeCompatibility was improved by reducing the PI errors (PISUM8) in these drives bymodifying the dye profile. Data has been shown in Technical Report (TR:DVDR/PROC/02/105 ) published for Cycle time reduction
  106. 106. Power Margin Data – Advance Media Lab
  107. 107. Power Margin Data – Advance Media LabConclusion : Advance Media Lab report, Drive compatibility data, Electrical /Mechanical data showsthat there is no significant change in disc quality in lower cycle time. All Data attached in TR:DVDRPROC02105
  108. 108. Control
  109. 109. Process Control SystemProcess Control SystemProcess Description:Optical disc manufacturingProcess Customer:IPQCCritical Business:High manufacturing cost ofDVD-ROutcome Indicator:Disc qualityChecking ItemsInput- Process-Outcome IndicatorsControl Limits Checking Item Responsibility Control PlanOtherInformationCooling ConveyorCycle Time<1.9 sec Stop watch Process / ProductionWeekly audit forcontrolling deviationTechnical reportapprovedDye Coating CycleTime<1.9secMachine Screen Process / Production Weekly audit forcontrolling deviationDryer Cycle time <1.9secStop watch / machinescreenProcess / ProductionWeekly audit forcontrolling deviationMetallizer Cycle Time<1.9 secProcess parameter Process / ProductionWeekly audit forcontrolling deviationBonding Cycle Time<1.9 secMachine screen Process / ProductionWeekly audit forcontrolling deviationFinal scanner CycleTime<1.9secFinal scanner screen Process / ProductionWeekly audit forcontrolling deviation
  110. 110. Impact of CYCLE TIME on Avg ProductivityAvg.machine output per day has been increased from 31985 (Avg Sept’11~Nov’11) to38595 (Avg Dec’11 ~March’12) disc during control phase
  111. 111. Validation of CYCLE TIME (Y)Ho: Avg production of CH-II with 1.90sec Cycle time = Avg. production of CH-II lineswith 2.3 sec Cycle TimeHa: Avg production of CH-II with 1.90sec Cycle time > Avg. production of CH-II lineswith 2.3 sec Cycle TimeTwo-Sample T-Test and CI: 1.90 sec CT, 2.3 sec CTTwo-sample T for 1.90 sec CT vs 2.3 sec CTN Mean StDev SE Mean1.90 sec CT 148 36460 1166 962.3 sec CT 152 31775 2199 178Difference = mu (1.90 sec CT) - mu (2.3 sec CT)Estimate for difference: 4684.4495% lower bound for difference: 4349.99T-Test of difference = 0 (vs >): T-Value = 23.13 P-Value = 0.000 DF = 231Here ‘p’ value < 0.05 So we reject Null Hypothesis and accept Alternate HypothesisConclusion :Avg production of Challenger-II lines with 1.90sec Cycle time is SIGNIFICANTLY HIGH ascompared to avg production with 2.3sec Cycle time
  112. 112. BOX PLOT- CYCLE TIME Y
  113. 113. GB Project : To reduce cycle time of CH-II Lines from 2.3 sec to 1.90 sec.Leader : ABCChampion : Dr. JSOMG Head : Mr. LKProject Benefits:Item Unit Values RemarkCycle time of CH-II lines after project Seconds 2.3 During Sept11 ~ Nov11Cycle time of CH-II lines after project Seconds 1.9 After Dec11Avg production of CH-II line per day BEFORE project No. of Disc 32185During Sept11 ~ Nov11 ( source data :GNNAS -DVD MIS )Avg production of CH-II line per day AFTER project No. of Disc 38396During Dec11 ~ April12 ( source data :GNNAS -DVD MIS )Increase in production per Line per Day No of disc 6211OEE BEFORE project percentage 85.00%Calculated from Data of Sept11~ Nov11( Data attached )OEE AFTER project percentage 85.00%Calculated from Data of Dec11 ~ April 12( Data attached )Gain In OEE percentage 0Gain in Production per line per day due to 3.06% increase inproductionNo of disc 0ACTUAL INCREASE IN PRODUCTION DUE TO CYCLE TIME- production per line per dayNo of disc 6211Number of CH-II lines Numbers 20Gain in Production No of disc 14906400 Production Gain during Dec11 ~ April12Rupees 41737920Crore 4.17Project Leader Project Champion OMG HeadAccounts HeadContribution earned at Rs 2.8per Disc
  114. 114. THANKSTHANKS

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