IRJET- Metastability Mitigation & Error Masking of High Speed Flip-Flop
SIP PPT
1. Pankaj Kumar
SIBM Bengaluru
Intern - SEIPL -Hyd
Improving OTDS/ISSR for export flows in an integrated supply chain using Six-Sigma (DMAIC)
methodology.
2. Problem Statement
2
.
Wha
t
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
WK-1
WK-2
WK-3
WK-4
WK-5
WK-6
WK-7
WK-8
WK-9
WK-10
WK-11
WK-12
WK-13
WK-14
WK-15
WK-16
WK-17
WK-18
WK-19
Jan-14 Feb-14 Mar-14 Apr-14 May-14
OTDS Trend
OTDS
Target
OTDS for export flow YTD is 77% against the target 96.5% for HYD Plant
Introduction
In today’s competitive business environment, customers require dependable on-time delivery;
On-Time delivery performance provides an indication of how successful the supply chain is at
providing products and services to the customer. Late deliveries contribute to excess inventory
holding costs, and loss of goodwill. Hence, It becomes essential to improve overall efficiency of
on-time delivery process taking into account production, shipment & transportation lead time.
D M A I C
3. Voice of Customers (VOC)
3
SELA & France
HUB
Marketing & Sales
Plant
Agreed Service Level
To meet customer demand.
Customer Service To retain customer, Business
Gain.
Reduction in Queue To get more business
WHO WHAT WHY
D M A I C
4. 4
NEED DRIVER CTQ’s
To Achieve
Agreed Service
Level.
Forecast Accuracy
Timely Dispatch
Prioritization
Output, Queue
Management
MOQ, Safety Stock, LT
Low Downtime
FYP
Transit Lead Time
Forecast
Logistics
Production Plan
Manpower
MRP
Downtime
Quality
Transport
Critical to Quality Tree D M A I C
9. MATERIAL
METHOD
MACHINE
Production
Planning Failure
MAN MEASURE
YICO – Production Planning Failure
Unskille
d Labor
Production Plan
not properly
followed
Changeover
Downtime
Comfort based
Load Sheet
Entry
RM Unavailability
at Supermarket
Test bench
Failure
Reluctance
in
Production
of Critical
Contractors
. Backorder
TreatmentEfficiency
constraints
High Queue
Capacity (7500) vs.
Actual Production
(5000)
D M I CA
10. Root Cause: Production Plan not Properly Followed, huge gap between production plan & load sheet
entry. (Attached).
Action Plan: Load Sheet vs. Production Plan need to be prepared daily, validated weekly& gap analysis
need to be shared.
Root Cause: Comfort based Load Sheet Entry by DVC’s.
Action Plan: Load Sheet entry need to be mandatory done by Production Shift Lead & need to share the
progress report every 3-4 hours.
Root Cause: Supermarket not ready, Material Unavailability.
Action Plan: Critical OTDS & Elephant Order need to be shared 3-4 days prior, So that supermarket can be prepared.
D M I CA
10
11. 11
Root Cause: Capacity vs. Actual Production, Actual Production is 5000 units against the capacity of 7500.
Action Plan: Capacity Dependent on three factors:
Man: A lot of DVC’s are new, Maintain 50:50 ratio among experienced & inexperienced labor, Put skilled DVC’s on main
U-Line
Machine: Machine downtime at test bench.
Material: Unavailability of Material at Supermarket, Provide production plan of critical OTDS order 3-4 days prior so that
material availability can be ensured & sub-assembly can be ready.
0
0.5
1
1.5
2
2.5
3
Fixed&MovingReviting
BaseAssembly
OutLetInsertion
OutLetScrewing
CoilWinding
CoilSoldring
CoilBending
CoilTesting
PCMAssembly
MovingCore&ArcSheildAssembly
FixingContactAssembly
FinalAssembly
Testing
Screwing
CoversAssembly
VisualInspection
Packing
ARCSheildPrinting
Covers&CoilPrinting
Rework
Off lines Coil u line Main U Line Pad printingRework
Skill Matrix
Minimum Skill
Average Skill
On Roll Off Role
Tesys-E On Roll vs Off
Role
35 72
Tesys - E On Roll vs. Off Role
DVC
0-6
Months
6-12
Months
1-3
Years
3+
Years
Tesys-E Manpower Seniority
72
27 11 8
Tesys -E Manpower Seniority
DVC
D M I CA
12. 12
0
5000
10000
15000
20000
25000
30000
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
YICO - Downtime Analysis
Downtime (In Min)
Comm. Percentage
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
YICO Process - Downtime Analysis
Downtime (in min)
Comm. Percentage
Bottleneck is
Changeover
time &
Machine
Breakdown at
Uline-1 & Test
Bench.
Root Cause: Changeover Downtime.
Action Plan: Implement an SMED to focus on reduction efforts on the setup time & machine downtime, specifically at test bench & U-Line-1
(YICO)., Sensor installed to sense pallet for different prod. Ref & Test bench probes need to be checked/maintenance on regular interval.
D M I CA
13. Root Cause: High Queue
0
5
10
15
20
Jan -Queue Real Max Min
0
50000
100000
150000
200000
JAN - PROD and ORD Forecast Orders Intake Qty Produced
0
5
10
15
20
Feb - Queue Real Max Min
0
20000
40000
60000
80000
100000
120000
FEB - PROD and ORD Forecast Orders Intake Qty Produced
0
2
4
6
8
10
12
14
16
Mar - Queue Real Max Min
0
50000
100000
150000
MAR - PROD and ORD Forecast Orders Intake Qty Produced
D M I CA
14. 14
YICO – Quality Issue
0
200
400
600
800
1000
1200
1400
1600
1800
2000
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
FPY Test bench -1
Rejected Qty
Comm. Percentage
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
FPY Analysis Test Bench -2
Rejected Qty
Comm. Percentage
Data Collection 1st May - 24th May
Tested Qty Rejected Qty Beating Travel Consumption PU RU HV FPY
102651 12941 2184 6248 1408 684 2397 20 87.39%
D M I CA
15. MATERIAL
METHOD
MACHINE
Travel Failure
Pressing of fixed
contacts
Gap between fixed &
Moving contacts tip
Magnet
dimension
work instructions
Fixture
selection and
usage
Placing of fixed
contact s into
arc shield
Gauge Calibration
MEASURE
Design of the fixture
YICO – Travel Failure
Placing
contractor in the
fixture.
Training
MAN
Fixed contact
dimension
Moving contact
dimension
Probe Reading
D M I CA
16. Quick Wins
1. Improper placing of fixed contact
2. Fixed contact dimension out at maximum side
3. Wrong specifications for travel testing
4. Improper pressing of fixed contact
5. Low gap between fixed & Moving contacts tip due to fixture base height is 2mm less
PRIORITIZATION
NS – Non significant S –Significant
To improve the FPY
from 56% to 96% of
32&38A contactors by
solving Travel failure.
40%
57%
45%
58%
51% 54%
96%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
FPY for 32&38A Contactors
FPY Target
D M I CA
17. Action plan:-
Added block to maintain 2mm gap between fixed & moving contact; Updated in dawning
Before: Jan’14 ~ Mar’14
After: May’14 ~ Jun’14
Before
Cp = 0.93
Cpk = 0.74
Before
Cp = 0.33
Cpk = 0.23
After
Cp = 1.65 Cpk = 1.48
After
Cp = 0.79 Cpk = 0.59
Block added to
maintain 2mm
gap b/w fixed
and moving
contact
Root cause:- Fixture base height 2 mm less
Why 2:-PCM not lifted
completely during fixation
of fixed contacts
5 D M I CA
18. Action plan:-
Informed to supplier about criticality of the part (fixed contact) and implemented checking at supplier end &
incoming inspection sampling size increased
After
Cp 1.05
Cpk 0.69
Fixed contact
Height: Before
Cp = 0.39
Cpk = 0.14
Root cause:- Fixed contact height is out of specification and measured 1.9 -2.8mm against 1.9-2.3mm
Incoming inspection
sampling check
sheet
Before: Jan’14 ~ Mar’14
After: May’14 ~ Jun’14
2 D M I CA
19. Action plan:-
Travel testing parameters modified from 1.02-
1.98 to 1.02-2.28mm
Before
CP1.22
and
CPK0.16
After
CP1.71 and
CPK0.97
0.3mm
Found the contact having an extra elevation of 0.3mm
contact having an extra elevation of
0.3mm
Root cause:-Found the contact having an extra elevation of 0.3mm unaccounted during the product spec
defining process(defined travel spec is 1.02-1.98 but actual should be 1.02-2.28mm )
Before: Jan’14 ~ Mar’14
After: May’14 ~ Jun’14
3
D M I CA
20. Action plan:-
Support added to hold the arc shield
Action plan:-
Fixture developed to avoid wrong placing of fixed
contact into arc shield
1 4
Why1:-Product one side tilting during pushing,
Why 2:-No support from top side to arc shield
Root cause:- No support to hold the arc shield
Why 1:-Wrong Placing of moving contact into arc shield
Why 2 :-Manual placing of contacts
Root cause:- No control in the line to avoid manual assembly
Before: Jan’14 ~ Mar’14
After: May’14 ~ Jun’14
D M I CA
21. 21
YICO –Quality Failure
Dust on Magnet Core
leads to Quality Failure.
Fix a glass chamber
at line to place core
to avoid dust.
Improper Spring Fixing.
Manual Error, Put
Experienced DVC for
this Job.
Check if contacts
dimensions are as
per design after
delivery.
Replace
contacts if
required.
Probe at Test Bench need to be
check at regular interval
maintenance drive which is not
happening.
Replace & Rework on
Scheduled dates.
D M I CA
22. 22
YICO – Quality Failure
Improper fixation of
fixed contacts leads
to bend.
Fixture needs to
check & replace if
required.
Manual Placing of
moving contact into
arc shield
Manual Error, Put
Experienced DVC for this
Job.
Manual Placing of
Contractor on Fixture.
Manual Error, Put
Experienced DVC for this
Job.
D M I CA
23. MasterPact – RM Shortage
OTDM failed due to following RM references.
S1A84348D
S1B96420D
S1B27865
21637188
Stocking Policy of these
references reviewed &
updated.
MasterPact – Elephant Order
Elephant orders of Chassis received due to which OTDM lines got failed.
Cause: Elephant Order Tracking of Export flows are not happening.
Action Plan: Elephant Order needs to be Tracked as per the committed dates &
seek if there room in getting the next committed date else Elephant Orders
needs to be informed prior to Production so that Sub-Assembly can be
prepared.
D M I CA
23
24. 24
Transit Failure
0
50
100
150
200
250
300
350
400
450
Dispached On
Time
OTDS Delay
416
82
Transit Delay
Dispached On Time
OTDS Delay
0
10
20
30
40
50
60
70
80
Transit Delay Delivered On time
Based on DSR report ETA
2
80
Transit Delay Breakup
GRN Delay,
Updated to SELA
Action Plan: Tracking of Delivery based on ETA included in Daily
Practice. DSR to be undated according to Logigram.
34
31
9
4 3 1
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
0
5
10
15
20
25
30
35
40
Transit Delay RCA
Lines
Comm. Percentage
D M I CA
25. Before After *Projected
1. Determine number of defect opportunities per unit O = 1
2 Determine number of lines N = 504
3. Determine total number of defects made D =
(include defects made and later fixed)
32
4. Calculate Defects Per Opportunity DPO = D / (N x O ) 0.05
5. Calculate Yield = (1 – DPO) x 100 = 94%
6. Look up Sigma in the Process Sigma Table
Process Sigma = 3.2
Process Sigma from 2.11 3.2
1. Determine number of defect opportunities per unit O = 1
2. Determine number of lines N = 504
3. Determine total number of defects made D =
(include defects made and later fixed)
137
4. Calculate Defects Per Opportunity DPO = D/ =
N x O
0.27
5. Calculate Yield = (1 – DPO) x 100 = 74%
6. Look up Sigma in the Process Sigma Table
Process Sigma = 2.11
D M IA C
25
