The project aimed to reduce inspection cycle time at Celestica Laguna Inc. from 72 hours to 20 hours and increase inspector productivity. Issues identified included insufficient manpower, a manual paper-based inspection process, and outdated equipment. The team developed a computerized inspection records system, trained inspectors, and reorganized the inspection area. Initial results were positive, with two inspectors successfully using the new system. Further improvements to automated reporting were planned.

1. 1
Project Title
CLI-IQA Cycle Time Reduction and Inspector Productivity Improvement

2. 2
Project: Improvement of CLI –IQA Inspection
Turn around Time and Productivity
Project Start: January 2, 2007
Project End: July 31, 2007
Location: Laguna, Philippines
Champion: Lito FLores
Process Owner: Ferdinand Cruz
Green Belt: Ferdinand Cruz / Jonash Rocamora
Team Members: Joszal Anchoriz, Alvin Ibanez, Tina
Mendoza, Sunny Caparas
Problem Statement:
After the acquisition of Powerwave Philippines by Celestica (Mar 2006), now known as Celestica
Laguna Inc. Different commodity network Teams (e.g. IC, Logic, Metals, PWB, Discrete, Passive,
Power Supply, Optics and Plastics ) and metrics ( e.g. Turn Around Time, SPM, SCAR etc.)
were introduced. The separation/resignation of two IQA inspectors (Reinor and Myla) and the
addition of new products such as Halfdome (April 2006) and Royale (July 2006) resulted to
massive parts queue for inspection at IQA. Previous Inspection turn Around Time (cycle time)
from an average of 72 hours to 20 hours Celestica corporate/regional requirement should be met.
Regular submission of reports such SQE Global reports, Supplier Performance Measurements
(SPM), Supplier scorecards should also be accomplished and submitted.
Objective Statement:
• Improve inspection cycle time from previous average target of 72 hours to average of 20 hours.
• Maximize IQA space to accommodate more parts queue for inspection.
• Increase inspectors productivity by 20% from average of 17 line items inspected to 20 line items
(without NCMR) for 10 hr/shift work schedule and 7 to 12 line items with some NCMR.
• Fast and accurate data retrieval from manual paper trail to computerized data miner
Current Project Savings: To be computed/ To be determined
Project Phase:
Accomplishments:
 Team formation/ Organization, DONE ww01 2007
 Macro Mapping of Process , DONE ww01 2007
 Data Gathering , DONE ww02 2007
 Data Analysis, DONE ww03 2007
 Program logic / flow discussion with IT, DONE ww04
 Programming of sub-modules and major modules including screenshots, Started ww05 2007
 Review/test completed sub modules and major modules, ww06 2007
 Program debugging ( as needed)
 Part number set-up and inspection requirement set-up, Started ww07 2007 as needed.
 Set-up hardware requirements and PR additional requirement to support full
implementation. DONE ww07, 2007
 Review IQA layout and material flow. DONE ww07 2007
 Re-layout IQA according to plan. DONE ww7 2007
 Train IQA inspector on how to use the program ww08 2007
 Start parallel paper trail method and automated QA records, DONE ww08 2007 (All Inspectors)
 Roll-out automated QA records without paper QA records with two inspectors.
 Linked QA records to MID system eliminating redundant encoding of parts traceability, 4/15/07
 Full implementation of Automated QA records to all IQA inspectors, May15, 2007
 Auto report (SQRR) module, May 15, 2007
To Do’s:
 Pilot run Auto report (SQRR) on ww21 report
 Enhance Auto reports program (SQRR) Target Date June to July 2007
 Revise IQA procedure to document the system change , Target Date June 2007
Project Summary:
Completed QA records minor and major modules programming. Started using the QA
records parallel with the manual paper trail method for comparison and buy-off purposes.
Pilot run of the QA records were successful . Two inspector were tasked to use the QA
records without the paper trail (inspection records). Daily review of the QA records
shows that the two inspectors were able to utilize the system properly. Full benefits of the
system will be realized after completion of the auto reports generation and
auto IDR/IR generation in case of failed inspection result.
Opportunities:
(Consider the next utilizations of achieved results)
Six Sigma Project Summary
D M A I C

3. 3
Project: Improvement of CLI –IQA Inspection
Turn around Time and Productivity
Project Start: January 2, 2007
Project End: July 31, 2007
Location: Laguna, Philippines
Champion: Lito FLores
Process Owner: Ferdinand Cruz
Green Belt: Ferdinand Cruz and Jonash Rocamora
Team Members: Joszal Anchoriz, Alvin Ibanez, Tina Mendoza, Sunny Caparas

4. 4
Problem Statement:
After the acquisition of Powerwave Philippines by Celestica (Mar 2006), now known as Celestica
Laguna Inc. Different commodity network Teams (e.g. IC, Logic, Metals, PWB, Discrete, Passive,
Power Supply, Optics and Plastics ) and metrics ( e.g. Turn Around Time, SPM, SCAR etc.) were
introduced. The resignation of two IQA inspectors and the addition of new products such as
Halfdome (April 2006) and Royale (July 2006) resulted to massive parts queue for inspection at IQA.
Previous Inspection turn Around Time (cycle time) target of 72 hours from the time parts received at
IQA until parts approval were not measured effectively since the current ERP (Baan) system measures
the cycle time from Receiving time up to part approval. Currently 20 hours T.A.T. Celestica
corporate/regional requirement should be met. Regular submission of reports such SQE Global
reports, Supplier Performance Measurements (SPM), Supplier scorecards should also be
accomplished and submitted on time.
Objective Statement:
• Effectively measure IQA inspection cycle time and meet 20 hours target.
• Maximize IQA space to accommodate more parts queue for inspection.
• Increase inspectors productivity by 20% from average of 17 line items inspected to 20 line items
(without NCMR) for 10 hr/shift work schedule and 7 to 12 line items with some NCMR.
• Fast and accurate data retrieval from manual paper trail to computerized data miner
Current Project Savings: To be computed/ To be determined
Six Sigma Project Summary

5. 5
Project Phase:
Accomplishments:
 Team formation/ Organization, DONE ww01 2007
 Macro Mapping of Process , DONE ww01 2007
 Data Gathering , DONE ww02 2007
 Data Analysis, DONE ww03 2007
 Program logic / flow discussion with IT, DONE ww04
 Programming of sub-modules and major modules including screenshots,
Started ww05 2007
 Review/test completed sub modules and major modules, ww06 2007
 Program debugging ( as needed)
 Part number set-up and inspection requirement set-up, Started ww07 2007 as needed.
 Set-up hardware requirements and PR additional requirement to support full
implementation. DONE ww07, 2007
 Review IQA layout and material flow. DONE ww07 2007
 Re-layout IQA according to plan. DONE ww7 2007
 Train IQA inspector on how to use the program ww08 2007
 Start parallel paper trail method and automated QA records, DONE ww08 2007 (All Inspectors)
 Roll-out automated QA records without paper QA records with two inspectors.
 Linked QA records to MID system eliminating redundant encoding of parts traceability, 4/15/07
 Full implementation of Automated QA records to all IQA inspectors ,DONE May 15, 2007
 Auto report (SQRR) module, May 15, 2007
To Do’s:
 Pilot run Auto report (SQRR) on ww21 report
 Enhance Auto reports program (SQRR) Target Date June to July 2007
 Revise IQA procedure to document the system change , Target Date June 2007
Six Sigma Project Summary
D M A I C

6. 6
Project Summary:
Completed QA records minor and major modules programming. Started using the QA records
parallel with the manual paper trail method for comparison and buy-off purposes. Pilot run of the
QA records were successful . Two inspector were tasked to use the QA records without the
paper trail (inspection records). Daily review of the QA records shows that the two inspectors
were able to utilize the system properly. Full benefits of the system will be realized after
completion of the auto reports generation and auto IDR/IR generation in case of failed
inspection result.
Opportunities:
(Consider the next utilizations of achieved results)
Six Sigma Project Summary

7. 7
Team Organization
Lito Flores
(Champion)
Ferdie Cruz
Jonash Rocamora
(Green Belt)
Team Members
Joszal Anchoriz
Sunny Caparas
Alvin Ibanez
Tina Mendoza

8. 8
Macro Map
Parts received
from supplier
at Receiving
QTY Audit
verification
Baan/System
Encoding
Endorse item
to IQA
Record to
logbook
Refer to
priority list
from Planning
Perform
Inspection
Prepare
Quality
Records
Baan
Transaction
MID
Generation
Prepare
NCMR
Receiving
Process Non-Value
Add
Non-Value add
but essential
Record to logbook X
Refer to priority list from planning X
Perform inspection X
Baan Transaction X
MID generation X
Prepare Quality records X
NCMR Preparation X
Endorse parts to warehouse & log X
Note:
Process inside dotted
lines are activities outside
IQA
Endorse parts
to Warehouse
and log to
logbook

9. 9
Data Gathering
Productivity Monitoring (1 month Data)
•Highlighted in yellow are not full time inspectors
•Highlighted in gray are new inspectors
•Encircled are the max line items inspected by full time inspectors
•Maximum Line items that can be inspected in a 10 hr shift schedule = (14+19+19) / 3 = 17 line items (without Failure/NCMR) using old
inspectors as base line.
•Average Line items that can be inspected in a 10 hr shift schedule with some NCMR preparation = (6+6+9) / 3 = 7 line items

10. 10
Analyze
Inspection Turn
Around Time
People Materials Work Methods
Environment Equipment
Skills
Education
Work
Attitude
Not Motivated
Low Salary
High Volume
Large geometry and
parameters to inspect
Manual paper Trail
method
Inspection,
endorsement,
approval, docs done
by one inspector
Insufficient
manpower
Not comfortable
Warm / cold
Crowded work
space
Sharing of test
equipment
Proximity to
inspection area
(CMM, ht gages
etc.)
Old equipment
`
Uses Baan

11. 11
Analyze
Received
parts from
Receiving
Allocate
parts to
inspectors
Perform
Inspection
Baan
Transaction
MID
Generation
Quality
Records
NCMR/
IDR
Endorse
Parts
Record parts
details on
log sheet
PO#/ /Receipt
#
Quantity
Record
endorsement
details on
log sheet
Endorse by
Received
by
Inspect
according
Refers to
priority list
Inspect
according to
age
Waiting for
priority list
from
planning
Waiting
for part
age
status
from IT
AML Check
Refer to
Baan for
AML Check
Visual
inspection
Dimensional
Inspection
Electrical
test
Create NCMR
manually
System
rejection
Refers to
quality
record and
master list
Manually
Record parts
traceability
details
Auto
generate MID
number
Part No
Lot code/date
code
Manually
Record parts
traceability
details
inspector
IR No./ Part
Number
Redundant /
repeated
Take picture
Manually
Draft the
report with
parts details
Create IDR
manually for
MRB
purposes
Manually
write parts
rejection
details and
inspection
details
Manually
pull-out
quality
records
folder
Endorse
parts to ware
house
Record
endorsement
details on
log sheet
System
Approval

12. 12
Analyze
Current VSM Considering no failure
Note: Highlighted in yellow are process that
can be improved
IQA VSM Before

13. 13
Improvement

14. 14
Analyze
Activity Off the shelf Item
(e.g. Component)
Approval 0.717
Inspection 8.317
Manual/Paper Method 10.000
Staging and
Endorsement 2.850
Traceability 10.517
Total 32.400
Off the shelf Item (e.g. Component) Inspection Elements
2%
26%
31%
9%
32%
Approval
Inspection
Manual/Paper
Method
Staging and
Endorsement
Traceability

15. 15
Analyze
Custommized Items (e.g. Mech'l, PCB, Cable) Inspection
Elements1%
75%
11%
2%
11%
Approval
Inspection
Manual/Paper
Method
Staging and
Endorsement
Traceability
Activity Custommized Items
(e.g. Mech'l,
PCB, Cable)
Approval 0.717
Inspection 106
Manual/Paper Method 14.82
Staging and
Endorsement 2.85
Traceability 15.75
Total 140.137

16. 16
Analyze
Consumables Inspection Elements
3%
27%
35%
9%
26%
Approval
Inspection
Manual/Paper
Method
Staging and
Endorsement
Traceability
Activity Consumables
Approval 0.75
Inspection 8.1
Manual/Paper
Method 10.583
Staging and
Endorsement 2.849
Traceability 7.713
Total 29.995

17. 17
Main Program GUI’s

18. 18
MAJOR MODULES
ITEM MODULE DESCRIPTION USER SCREEN SHOT REMARKS
1 IR Form
Inspection
Report
From
Generates an excel
file with an
automated serial IR
number, a form used
by IQA to record the
quality inspection of
the item. (For hard
copy purposes)
ALL
IQA
Status Completed: This tool
create inspection report form
with smart serial numbers. This
also eliminates the purchase of
carbonized IDR forms used
during MRB and parts
disposition at IQA
Average IDR Form consumption
Is about 4 rims per month.
To be used for failed Status only
2 ITEM
STATUS
A module that is
designed to monitor
the flow of material
and its status at IQA.
It alerts all concern
engineer, planners,
managers, finance
personnel regarding
the item on
hold/pending at IQA.
ALL Status Completed: This session
allows SQE and IQA staff to
work continuously without
interruption from different
person making follow-ups and
asking for parts status.
Previously tracking of parts
status were done manually and
usually summary status were
released the following day. With
the use of this tool everything is
just a click away.

19. 19
MAJOR MODULES
ITEM MODULE DESCRIPTION USER SCREEN SHOT REMARKS
3 CYCLE
TIME
Tracks the actual
time and date
received of the
items endorsed by
receiving
personnel.
ALL
IQA
Status completed . This
modules eliminates manual
tracking of date and time the
parts were received, this is
essential for the computation of
actual inspection turn around
time. The inspector would just
have to key-in the receipt
number and all items contained
on that receipt will automatically
tagged with the actual date and
time it was received by IQA.
Target inspection completion
date is also computed
automatically. This replaces
manual recording and log
books.
4 QA
RECORDS
Maintains details
and status of
incoming
inspection per part
number (visual
inspection,
dimensional,
electrical and
document
requirement)
ALL
IQA
Status: In Progress, ongoing
elimination of program glitch.
This module will replace the
Quality Records folder that are
used to record and trace parts
history . In return purchase of
quality records folder is also
eliminated.

20. 20
MAJOR MODULE
ITEM MODULE DESCRIPTION USER SCREEN SHOT REMARKS
5 MID A system that
generate and print a
unique serial number
used to identify the
material after
inspection. (pass
tracking of material
used)
ALL
IQA
Status: Existing system during
REMEC times. This system was
modified to fit the current need
of Celestica Laguna operations.
Inspector can now assign MID
number in online or offline
mode. Previously when the
Baan system is down, parts
approval and MID generation is
not possible. With the
introduction of manual MID
session MID assignment is now
possible without any
compromise because the online
and offline database are the
same eliminating double MID
number.
6 DATA
MINER
The program is
design to gather
information and data
collection and can
extract information
in excel format. The
system support the
following modules:
MID, For Approval, &
Inspection Record.
ALL
IQA
Status: Completed. This tool
replaces the tedious method of
retrieving parts
history/traceability.
Previously, when parts info
such as lot code or date code is
required hard copies of quality
records are retrieved from
archive, but with this new tool
everything is available in just a
click of a finger tips.

21. 21
OTHER MAINTENANCE SUB-MODULE
ITEM MODULE DESCRIPTION USER SCREEN SHOT REMARKS
1 CYCLE
TIME
CALENDAR
Maintains
inspection working
days for cycle time
reference.
SYSTE
M
ADMIN /
CLERK/
SQE
Status: Completed. This sub-
module supports the Cycle
Time Module. The System
Admin/Clerk/SQE manage the
session by identifying the
dates without work schedule
such as weekends and
holidays which should not be
included in the cycle time
computation.
2 AQL SETUP Maintains the
Accept Quantity Lot
(AQL) table as
being referenced in
the QA Records
module.
SYSTE
M
ADMIN /
CLERK/
SQE
Status: Completed. The
System Admin/Clerk/SQE
manage this session by
defining the AQL percentage
and level according to define
lot size ranges.

22. 22
OTHER MAINTENANCE SUB-MODULE
ITEM MODULE DESCRIPTION USER SCREEN SHOT REMARKS
3 COMMODITY
TYPE
Maintains the list
of all commodity
type
SYSTE
M
ADMIN /
CLERK/
SQE
Status: Completed, This
session is manage by the
System Admin/Clerk/SQE in
reference with the commodity
grouping provided by
corporate/regional SQE. This
supports the QA records
module and the part number
set-up sub-module. This
identifies the commodity type
a part number belongs.
4 COMMODITY
CODE
Maintains the list
of all parent
commodity codes
in a commodity
group
SYSTE
M
ADMIN /
CLERK/
SQE
Status: Completed, This
session is manage by the
System Admin/clerk/SQE in
reference with the commodity
grouping provided by
corporate/regional SQE. This
supports the QA records
module and the part number
set-up sub-module. This
identifies the commodity
group where the part number
belongs.

23. 23
OTHER MAINTENANCE SUB-MODULE
ITEM MODULE DESCRIPTION USER SCREEN SHOT REMARKS
5 COMMODITY
GROUP
Maintains the list
of all commodity
sub-group codes
being mapped in
component part
numbers.
SYSTE
M
ADMIN /
CLERK/
SQE
Status: Completed, This
session is manage by the
System Admin/clerk/SQE in
reference with the commodity
grouping provided by
corporate/regional SQE. This
supports the QA records
module and the part number
set-up sub-module. This
identifies the commodity
group.
6 DEFECT
SETUP
Maintains the list
of all defects by
commodity
encountered at
incoming
inspection.
SYSTE
M
ADMIN /
CLERK/
SQE
Status: Completed, This
modules allows the System
Admin/Clerk/SQE to identify all
possible defects per
commodity. This support the
QA records inspection details.

24. 24
OTHER MAINTENANCE SUB-MODULE
ITEM MODULE DESCRIPTION USER SCREEN SHOT REMARKS
7 ITEM
STATUS (For
Approvals)
REMARKS
SETUP
Contains the list of
status of item in
for Item Status
module.
SYSTEM
ADMIN /
CLERK/S
QE
Status: Completed, In this
session the System
Admin/Clerk/SQE define
remarks category e.g. MRB,
Non COC etc.
8 LOCATION
SETUP
Contains the list of
all location of
defect
encountered at
incoming
inspection.
SYSTEM
ADMIN /
CLERK/S
QE
Status: Completed.
In this session the System
Admin/Clerk/SQE define all
possible location of defects
e.g. top, side, etc.

25. 25
OTHER MAINTENANCE SUB-MODULE
ITEM MODULE DESCRIPTION USER SCREEN SHOT REMARKS
9 PACK
SETUP
Contains the list of
all type of material
packaging.
SYSTE
M
ADMIN /
CLERK/
SQE
Status: Completed.
In this session the System
Admin/Clerk/SQE define all
possible packaging available.
This support the QA records
module
10 PART
NUMBER
SETUP
A module which
specifies the
details of the item
particularly the
commodity group,
type, and its
application.
SYSTE
M
ADMIN /
CLERK/
SQE
Status: Completed, This
session supports the QA
records modules. The
SQE/System Admin/Clerk
define parts New commodity,
commodity group and
commodity type details.

26. 26
OTHER MAINTENANCE SUB-MODULE
ITEM MODULE DESCRIPTION USER SCREEN SHOT REMARKS
11 UNIT OF
MEASURE
Contains the list of
all unit of
measurement for
media use at
incoming
inspection.
SYSTE
M
ADMIN /
CLERK/
SQE
Status: Completed. This is the
session where the unit of
measurement is define by the
System Admin/Clerk/SQE e.g.
cm, inches, mm, microns etc.
This supports the QA records
inspection details.
12 AML
Retriever
This module
allows the user to
check the existing
AML without using
the Baan
ALL Status: Completed

27. 27
OTHER MAINTENANCE SUB-MODULE
ITEM MODULE DESCRIPTION USER SCREEN SHOT REMARKS
13 COC Up
loader
Uploads the COC
softcopy into the
IQA database
ALL Status: Completed
Allows the IQA to upload soft
copy of COC into the system,
making future retrieval faster
and eliminate possible loss of
documents. It also lessen the
paper for retention that
requires space and other
resources.
14 Media Used Maintains the list
of all measuring
equipment used
SYSTE
M
ADMIN /
CLERK/
SQE
Status: Completed, This
modules allows the System
Admin/Clerk/SQE to identify
all possible MTE and
inspection media used during
inspection. This support the
QA records inspection details.

28. 28
Tangible Benefits
Factors Before EXPECTED
Recoverability of
data
Retrievable in couple of hours or even longer depending on
the extent or details needed.
With the use of data miner module of the data base, data
retrieval is possible in minute or less
Resources Required papers, forms, cabinet and large storage space to
house document for temporary repository and archiving.
Minimal resources needed, eliminated other forms being
used and the need for additional cabinets and space
for repository and archiving.
Accessibility/
availability
Used to take couple of hours to identify status of all raw
materials at IQA location, every line item has to checked
manually from time to time versus the list provided by IT
clerk. Information was disseminated to concerned person
thru phone call and e-mails.
Made readily accessible in real time. Engineers, Buyers,
Planner, Finance Personnel and Managers can now
view the actual parts status queue at IQA whether it
is For Inspection, HOLD, for MRB disposition, for
RTV, etc.
Record Security Paper records can be misplace, lost or damage over time Incoming quality material record (soft copy) is secured
and regularly back-up in the network and remote
location
Cycle Time
Measurement
Cycle time measurement is computed using a separate excel
file because the cycle time measured by Baan is from
the time of parts received up to parts approval in the
system. This includes the MRB time, hold time, receiving
time. Etc.
With the use of cycle time module, cycle time can be
measured automatically from the actual time of
endorsement of parts to IQA up to complete
inspection. Manual logging on logbook and
encoding on excel file was eliminated.
Savings Need to allocate CAPEX for the purchase of locally available
software.
Realized approximately $2800 of savings as the database
was developed in house
Connectivity Uses paper trail method, connectivity to ODC is not possible.
Current ODC capability is from SMT to Box build.
Linkable to ODC making traceability from IQA inspection
to Box built possible.
Productivity
monitoring
Monitors manually, checking done at the end of the shift or
every start of the shift.
Can determine productivity of each inspector quickly
through the data miner module.
Data Accuracy Summary of failure were collected and summarized manually Summary are populated automatically with the use of
data miner.
Headcount Requires replacement for the two resigned employee Man-hour requirement were covered by the productivity
improvement. Therefore replacement is not needed

29. 29
Intangible benefits
•Demonstrated CAN DO ATTITUDE, the team created a new tool even with limited
resources available. The limited working schedule and skills set has never been an
issue to the team to complete the project. The team patiently worked together and
reached their goal.
•TEAM WORK was exemplified by the team members. The member of the group are
from different departments with different tasks, but were able to work as one to reach a
common objective of making IQA operation easy. The teams synergy produced an effect
greater than the sum of their individual capabilities.
•The team’s morale was uplifted. The development of the project provided them
confidence and a sense of accomplishment. They feel proud of what they have done