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ESTIEM Lean Six Sigma Green Belt Project at Continental - Scrap Reduction

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The project was conducted during an internship by a student who had attended ESTIEM Lean Six Sigma Green Belt Course.

Analytics presented in the case is directional to original. The case is used when students are selected for Lean Six Sigma Green Belt Intership at Continental. In the selection process candidates need to suggest a better way to use data and analytics.

More information about about the course and opportunities can be found here: https://www.estiem.org/default.aspx?PageId=3824



Published in: Automotive
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ESTIEM Lean Six Sigma Green Belt Project at Continental - Scrap Reduction

  1. 1. Lean Six Sigma Project Scrap Reduction in Electronic Circuit Board Production Lassi Uusitalo Lean Six Sigma Green Belt Trainee
  2. 2. Public Continental Company Presentation Continental Corporation Overview 2017 05.09.2018 2Continental AG Since 1871 with headquarters in Hanover, Germany 235,473 employees worldwide 554 locations in 61 countries Status: December 31, 2016
  3. 3. Public Continental Company Presentation Continental Corporation Overview 2017 05.09.2018 3 Sales of appr. €44 billion ContiTech 14% Chassis & Safety 22% Powertrain 18% Interior 20% Tires 26% Sales by division in % Status: December 31, 2016 © Continental AG
  4. 4. For ESTIEMers Corporate Function Quality&Environment › Project was conducted on during summer 2017 › In one of the plants in Germany › Highly standardized serial production › Data is created based on real world observations for this project presentation Project Introduction Scrap Reduction in Electronic Circuit Board Production 5 September 2018 4CFQ&E, © Continental AG
  5. 5. For ESTIEMers Corporate Function Quality&Environment Project Leader: Lassi Uusitalo Team: Maintenance Specialist Failure Analysis Specialist Team Leader in Prodction IT / Data Specialist Sponsor: Plant Manager Project Charter Scrap Reduction in Electronic Circuit Board Production 5 September 2018 5 Project Goal: Find & eliminate the rootcause of a long standing problem of a repeated defect which has lead to customer returns. DMAIC - Time plan: Define: 06 / 2017 Measure: 06 / 2017 Analyze: 06-07 / 2017 Improve: 07 / 2017 Control: 07-08 / 2017 DEFINE MEASURE ANALYZE IMPROVE CONTROL There have been problems with different parts of the external housing and connectors being mechanically damaged during the production. Problem Description: CFQ&E, © Continental AG
  6. 6. For ESTIEMers Corporate Function Quality&Environment › Since March several customer returns of defected products from repeated mechanical damage in circuit boards › A very specific and systematic problem with a specific cause › A range of other unexplained mechanical damages Problem Description Scrap Reduction in Electronic Circuit Board Production 5 September 2018 6 DEFINE MEASURE ANALYZE IMPROVE CONTROL CFQ&E, © Continental AG
  7. 7. For ESTIEMers Corporate Function Quality&Environment Amount of Scrap Varies Over Time Scrap reduction in Electronic Circuit Board production 5 September 2018 7 DEFINE MEASURE ANALYZE IMPROVE CONTROL 1110987654321 4.0% 3.0% 2.0% 1.0% 0.0% Observation IndividualValue _ X=1.9% UCL=3.5% LCL=0.3% 1 I Chart of Scrap rate per week CFQ&E, © Continental AG
  8. 8. For ESTIEMers Corporate Function Quality&Environment Deployment Diagram Scrap reduction in Electronic Circuit Board production 5 September 2018 8 DEFINE MEASURE ANALYZE IMPROVE CONTROL CFQ&E, © Continental AG
  9. 9. For ESTIEMers Corporate Function Quality&Environment Fishbone Diagram Scrap reduction in Electronic Circuit Board production 5 September 2018 9 DEFINE MEASURE ANALYZE IMPROVE CONTROL Machinery Methods Manpower MeasurementsMother NatureMaterials Transport Scrap CFQ&E, © Continental AG
  10. 10. For ESTIEMers Corporate Function Quality&Environment Potential Problem Analysis Scrap reduction in Electronic Circuit Board production 5 September 2018 10 DEFINE MEASURE ANALYZE IMPROVE CONTROL Process Step Potential Problems Possible Effects Likely/Possible Causes Shaking during manual handling Circuit boards bump into each other Loose shelves without up/down movement prevention mechanism Circuit boards are not aligned in the logistics box The vertical plastic part touches various areas of the circuit board above it Slippery non-fixed shelves ICT Misplacing the reader Misread in testing (non-failure read as failure) Mechanical and/or calibration problem Too hasty handling Carelesness The jig is too tight? Change in equipment pieces Forgetting reprogramming Gets stuck midway Too snug fit of the jig Unwelcome stress on the hinge between the microchip and the connector Handler lifts the microchip+connectors from one corner, creating an angle which causes the microchip+connectors to slide against the walls of the jig Parts which should be pressed end up in scrap Laser scanning is not suitable for checking the alignment of pieces? Parts which scrapped go through the press Lhe scanner is dirty? -> parts get further damaged down the line Wrong calibration? Awkward position of the operator The connectors could be set with a bit of an incorrect angle The jig is positioned in around 40 degree angle when outside of the machine The microchip is taken out forcefully Unnecessary stress on components Tight schedule, haste Loading Pressfit (connectors) Misplaced connector in the jig Pieces are not completely aligned -> pressfit will merge them with error/defect Calibration problem Several types of errors The assembled microchip+connectors are taken out at the wrong angle (not straight up) There is a reading error in the scanner before pressing › Done for all process steps › 32 Possible causes identified › How to get data? › Where to focus? CFQ&E, © Continental AG
  11. 11. For ESTIEMers Corporate Function Quality&Environment Pareto from Scrap Analysis Results Scrap reduction in Electronic Circuit Board production 5 September 2018 11 DEFINE MEASURE ANALYZE IMPROVE CONTROL Measurement points ICT test Check the alignment and connectors Check the result Check the seal EOL testing ICT Testing Machine Press Fit Machine 1 Paste Machine Hand press EOL Test Machine Count 928 207 48 60 Percent 74.7 16.7 3.9 4.8 Cum % 74.7 91.3 95.2 100.0 Subscripts OtherICT Testing MachineHand pressEOL Test Machine 1400 1200 1000 800 600 400 200 0 100 80 60 40 20 0 Count Percent Pareto Chart of defects per location CFQ&E, © Continental AG
  12. 12. For ESTIEMers Corporate Function Quality&Environment Process Steps for Paste Machine and Press fit Scrap reduction in Electronic Circuit Board production DEFINE MEASURE ANALYZE IMPROVE CONTROL Place housing pieces in the paste machine Place pasted housing pieces on the pre- assembly table Place circuit board in the assembly jig Place pasted upper housing in the assembly jig Place the battery in its slot Place & press the battery protector w/ handpress Place the upper+ lower housing in the final (small) pressfit Apply paste Seal the upper and the lower housing together Flash the tracking barcode of the battery Check the seal Check the result Place the tracking label on the product Operator 2 Paste Machine Hand Press Scrap Analysis CFQ&E, © Continental AG 5 September 2018 12
  13. 13. For ESTIEMers Corporate Function Quality&Environment Weeks 14 to 16 Have the Highest Scrap Rate Scrap reduction in Electronic Circuit Board production 5 September 2018 13 DEFINE MEASURE ANALYZE IMPROVE CONTROL Counts EOL 270 152 138 108 93 80 49 38 Percent 29.1 16.4 14.9 11.6 10.0 8.6 5.3 4.1 Cum % 29.1 45.5 60.3 72.0 82.0 90.6 95.9 100.0 Defects in EOL O ther problem in Antenna 23 Protocol 1 problem in connectors 12-14 Protocol 2 Protocol 3 Protocol 4 problem in connectors 1-3 900 800 700 600 500 400 300 200 100 0 100 80 60 40 20 0 CountsEOL Percent Pareto Chart of Defects in EOL Most problems are occurring with connectors CFQ&E, © Continental AG
  14. 14. For ESTIEMers Corporate Function Quality&Environment Weeks 14 to 16 Have the Highest Scrap Rate Scrap reduction in Electronic Circuit Board production 5 September 2018 14 DEFINE MEASURE ANALYZE IMPROVE CONTROL Counts 155 52 Percent 74.9 25.1 Cum % 74.9 100.0 Defects in Hand Press Connector 12Connector 23 200 150 100 50 0 100 80 60 40 20 0 Counts Percent Pareto Chart of Defects in Hand Press Most problems are occurring with connectors CFQ&E, © Continental AG
  15. 15. For ESTIEMers Corporate Function Quality&Environment Closer Look at the Fishbone Diagram Component Breakages Detected After Hand Press 5 September 2018 15 DEFINE MEASURE ANALYZE IMPROVE CONTROL Machinery Error In Hand Press Wrong setting Mounting component incorrectly CFQ&E, © Continental AG
  16. 16. For ESTIEMers Corporate Function Quality&Environment Problem Potentially Caused by Wrong Setting Problems started occurring after latest maintenance 5 September 2018 16 DEFINE MEASURE ANALYZE IMPROVE CONTROL › Handpress has been set to go lower than the top of the assembled part › There is excess force inflicted on the parts in the hand press station › All force that is not used for clipping the battery cap is directly transferred to the circuit board, causing it to bend CFQ&E, © Continental AG
  17. 17. For ESTIEMers Corporate Function Quality&Environment Improvements Contact of Antenna and Housing in Hand Press 5 September 2018 17 DEFINE MEASURE ANALYZE IMPROVE CONTROL Recalibration of the hand press Strain gauge measurements Immediate improvements Making a new reference block Additional supports on hand press jig Long-term improvements CFQ&E, © Continental AG
  18. 18. For ESTIEMers Corporate Function Quality&Environment Any Questions? Thank you! 5 September 2018 18CFQ&E, © Continental AG
  19. 19. For ESTIEMers Corporate Function Quality&Environment › Common for all is the structured approach for solving problems › Always need for data to support the process and validate improvements › Six Sigma is the most data focus approach › Tools are used flexibly, no matter how the approach is called! Lean Six Sigma in Automotive Industry Need for Structured Problem Solving 5 September 2018 19 DEFINE MEASURE ANALYZE IMPROVE CONTROL A3 8D Six Sigma CFQ&E, © Continental AG

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