提高个人产值30%

112/09/2008Champion:JeffWeiProjectLeader:EricLHLiuTeamMembers:LinnaXieQAJoyXiaIEZolaZhouPEJackyTangPSEKevinQChenPMEJerryYuanFAPD提升FA個人產值30%2R1Define3IDOpportunity個人產值提升30%PCBA個人產值提升30%FA個人產值提升30%RCTO個人產值提升30%3)Drilldownagaintofind(theSubY’s)1)Startwithbusinessgoal2)Identify/quantifytheinputs(theBigY)4)Letthedatauncoverthe(Smally’s)SuccessDerivedfromProjectFocusDefine-SelectProjectCustomer’sforecastFAdailyoutputHeadcountAssemblyWindowsdownloadPre-runinRuninPacking•Ass’ytime•MOH•FPYR•Imagesize•ServerQty•Testingtime•Testitems•Testtools•Runintime•Imagesize•Runinrackcapacity•LabelQty•AccessoryQty4Target:1.Monthlyoutputofpersonalupto252units/M(Wholeyears-KPI)2.Monthlyoutputofpersonalupto291units/M(6sigmaphasein)*選擇Y07的個人產值平均值再提升50%.Y2007average:194unitsTarget:194*(100%+50%)=291unitsDatafrom:WKSPlantII2007finalOperationPlatform:consumerandcommercialandnotincludedockingTimeRange:Jan’07toDec’07FA個人產值StatusDefine-SelectProject1.客人盤點,訂單下降2.黃金周放假PCBA為8月提前備一條線人力1.FAPre-buildmanpowerforMay2.新機种量產(Viking)1.年終槃點2.FA多備一條線人力for春節離職替補春節2007年終盤點5TeamCharterBusinessCaseThisprojectsupportscustomerrequirementandcorporategoalbyimplementingProcessImprovementintoWistronWKSFAproductionline.ByimprovingtheFAproductivity,wewillimproveFAPersonaloutput.OpportunityStatementWecurrentlyhaveoutput194units/personatFAprocess,Thereisgreatchancethatwecanincreasethe291units/person.GoalStatementTarget:•提升FA個人產值從194unit/monthto291•units/month(Y1).•FinancialIndicator:TotalCostSaving:RMB:5121KRMB•Sideeffectindicators.MOH:0.94%(Y2)FAFPY:98.1%(Y3)OOBdefectrate:500DPPM(Y3)AFR:8.0%(Y4)ProjectScopeWKSPlant2NBProducts.(dockingisnotinclude).FA→Start:FAMOreleaseStop:FAStore-inProjectPlanTeamSelectionControlImproveAnalyzeMeasureDefineSepAugJulJunMayAprMilestoneContributionJeffWeiEricLHLiuJoyXia/IEZolaZhou/PEKevinQChen/PMEJerryYuanLinnaXie/QAJackyTang/PSEChampionBlackBeltLeaderGreenBeltGreenBeltGreenBeltGreenBeltGreenBeltGreenBelt10%20%15%15%15%15%5%5%Define-TeamCharterPlanActual6•___________•___________•___________•___________•___________•___________•___________•___________•___________•___________•___________•___________fFinalAssemblyProcessStart:MOReleaseSupplierInputOutputCustomerBoardsComponentsPCBAPDPartsvendorWistron/AstroMaterialPrepareAssemblyPre-inspectionProcess1/2•___________•___________•___________•___________•___________•___________•___________•___________WindowsdownloadSIPOCMap1/2MOschedulePMCTestImageTES/WShippingImageCustomerConfirmMOMEpartsassemblyLCD/DIMM/HDDpartsassemblyBatteryassemblyCosmetic,gap&stepinspectionDownloadimagefromsystemAutolinkSFCSsystemViewNRPofY2008andCTOPOis5%-10%VSoverall,weshippingCTOmachinetoHPregionsameasBTO.Soweneedn’tspeciallycontrolCTOprocess.CPUassemblyScaninSFCSsystem大庫房準備PRT領料單從大庫房領料領MOBOM按BOM發料給產線Review缺料Maintain缺料MOreleaseDefine-MapProcess1.Monthlyoutput2.FAFPY3.OOBD.R4.Shippinghitrate5.CoPQ7Finaltest•___________•___________•___________•___________fFinalAssemblyProcessPreRun-inSupplierInputOutputCustomerBoardsComponentsPCBAPDPartsvendor1.Monthlyoutput2.FAFPY3.OOBD.R4.Shippinghitrate5.CoPQWistron/AstroRuninPostinspectionPackingProcess2/2•___________•___________•___________•___________••___________•___________•___________•___________•___________•___________•___________•___________•___________•___________•___________•___________End:StoreinSIPOCMap2/2MOschedulePMCTestImageTES/WShippingImageCustomerWindowstestDOStestDOSruninWindowsruninPreloadshippingImageSystempackingScaninSFCSsystemWipingLoadingViewNRPofY2008andCTOPOis5%-10%VSoverall,weshippingCTOmachinetoHPregionsameasBTO.Soweneedn’tspeciallycontrolCTOprocess.AutolinkSFCSsystemAutolinkSFCSsystemCosmetic,gap&stepinspectionScaninSFCSsystemDefine-MapProcess81.個人產值增加，不同的会计科目的变化如下：-費用增加(11%):間接材料,工具室領用,雜項購置-費用不變(89%):人事費用,折舊,水電,Site分攤……2.Y2007capacitycompare:consumer=2*Commercial,以Consumer为基准CommercialMOH=2.12(0.89*2+0.11)=4.00USD3.Y2008capacitycompare:consumer=1.2*Commercial,以Consumer为基准CommercialMOH=2.12(0.89*1.2+0.11)=2.49USD4.OPPFACapacitywillup30%:以consumer为基准：OPPMOH=2.12*(0.89/1.3+0.11)=1.68USD5.TotalMOH=Σ(Expense/Shipment),TotalExpense=TotalMOH*全年Shipment2007ShipmentbaseonActualShippingQuantity,2008ShipmentbaseonJan~AprActualShipment+LTFAprOPPCapacityUp30%,Total费用与Consumer比较分摊到会计科目后百分比：其中不变费用占89%随着产能同比增加占11%執行專案成本評估2,990,00090,322,591改造新增設備投資87,332，591改善後費用分為兩個部分1.MOH部分預算按照Y2007Rate遞延分攤2.新增的投資部分作為額外部分另加計算Define-FinicalEstimation9R2Measure10CEdiagramMeasure-CEdiagram透过Brainstorm收集可能对各段(Smally’s)产生影响的因子,并将初步判定为重要的因子作标识如红色的圈1112CEMatrixMeasure-CEMatrix30个得分大於50分的因子挑選出來作為重要因子,其中22个因子可以做QuickWin,1個因子為fix的DLheadcount,還剩下7個重要因子.1.Listthekeyoutputstotheprocess.2.Rateeachoutputona1-10scale.Andpotentialsideeffectindictor.3.Listtheinputsandprocesssteps.Usetheprocessmapandfishboneforinputs.4.Rankeachinputastohowitaffectseachoutputona0(無關係),1(弱),3(中),9(強)scale.5.SorttherowsbasedontheTotalcolumn.Theinputsarenoworderedbycustomer'spriorities.13QuickactionforX’Measure-CEMatrixTotal22个因子以Quickwin的方式來解決,具體參考以上table,另外一个為需要被fix住的“DLheadcount”Item流程/輸入(X's)ScoreAction費用預算PICDueda