盈聚电子制程优劣势分析-韩文0825

DongguanCityYingJuElectronicsCo.,Ltd2012.08.25Strengths/WeaknessAnalysisofYingJuProcess--2012--作成者:徐熙审核:王永安裁决:曾昭伟제작공정우수사례와부족점1.선진적인생산설비와제작공정이구비됨.2.자동납땜의품질양호하고불량율을200PPM이하로공제하고있음.3.적외선고도측량기계가도입되었고측량정밀도제고시킴.4.ICT측량기계가선진적이고전해콘덴서극성역방향측정가능,측정율이95%이상도달함.5.에징룸의자동온도공제시스템및AutoMonitor시스템이도입되었고에징룸의상태를감시하고공제할수있음.6.제작공정불량예방대책이실시됨,제작공정검출능력이강화됨.제작공정우수사례개선중의부족점자동화개선추진중의부족점:1.선입선출을시스템으로관리하지못하고있음.2.완제품자동테스트선,테스트기종이다양화안됨,가동율(嫁动率)낮음.SMPS제작공정AI/SMTWaveSoldringH/IT/UICTATE1ASS’YASS’YTestUltrasonicB/ITestH/PTestOutputRippleATE2PackingShipmentQA/OQCPassQCQCQCQCQCA기종투입B기종투입수삽솔더링자동분리터치업ICTATE1ASS’YB/IH/PRippleTestATE2PackingShipment제작공정우수사례설명과제신뢰성불량의예방（MIStation)●목적：부속품의들뜸에대한대응예방조치솔더머신에투입전덮계지그를사용,부속품의들뜸을방지.삼성기종은전문덮계지그를사용,기타기종은다른지그를사용함.제작공정관리우수설명과제자동납땜불량율공제에대한대응●목적：납땜품질의상승（신솔더머신의자동납땜품질을200PPM이하로공제）예방조치신솔더머신扰流波의개조，扰流波홀위치가변경됨.扰流波의평온을위함,CHIP부속품의납땜의누락이감소되고납땜이균일함;부속품에대한충격이낮아지고부속품들뜸현상이줄어듬.불량율이원래의1025PPM200PPM变更전变更후과제ICT검출력의상승●목적：大콘덴서역삽입방향검출력의상승（ICT검출력이95%이상）예방조치ICT테스트지그의개조,대콘덴서의역방향검출을위함.대콘덴서의역삽입유출을방지함으로써엄중한불량을방지.ICT측정율이원래의80%93%E-CapTest증가，역홀ㅂㅏㅇㅎㅑㅇ검출가능함.제작공정관리우수사례설명과제신뢰성문제방지●목적：적외선검사의방법으로제품의높이를보증하고조립을보증.예방조치적외선테스트지그를사용,PCBA높이를보증，융착시불량을방지，신뢰성불량을방지。높이의정밀도0.1mm이하로공제。고도마이크로미터조정적외선발사접속Sensor제작공정관리우수사례설명과제Burn-In테스트Monitor시스템，검출력상승●목적：Burn-In과정중monitor진행함으로써전압불량을방지,검출력상승.예방조치Burn-In전자부하방식을채용,전압은monitor전압방법을채용,전압상태를감시/공제,검출율상승.제작공정관리우수사례설명과제자동라인추진●목적：자동테스를통해효율을높이고검출력을제고.예방조치자동선설계시한개기종만적용됨,현재개선중,10월말에완성될것으로예측.불량품을로보트로자동으로꺼냄.제작공정관리우수사례설명과제선입선출관리개선●목적：현재선입선출방법을관리하고ERP시스템을도입할계획예방조치창고관리방법1:월간라벨색갈별로선입선출을관리.방법2:물량리스트에반드시선입선출해야할자재를명시.ERP시스템에자재Bar-code의선입선출관리를도입,12.30완성될것으로예측.과제선입선출관리개선●목적：ERP시스템선입선출관리의추진완성일자2012.12.30예방조치영취전자부족점추진계획LotNo.입력LotNo.선입선출자동식별후자재발급ERP시스템명칭TF팀조직도조직도:副总经理曾昭伟王永安徐熙QC张成福杨威IE廖常军TE郑敏敏MFG程用辉ME陈美淩WHSupporter陈艳平13개선방향ESD2012年개선활동6대개선방향:자동화설비加工成型신뢰성실험B/I테스트부품포장제작공정직통율(直通率)과제에징온도공제시스템개선Quality□效率向上■工程改善□不良改善□受率向上구분담당자부문기간개선대책Cost□改善VE□购买引下제출인SamsungCustomer5/30’12□AcceptDelivery□纳期缩短□Capa增加■Process改善검토张成福YJ/PIE6/19’12□Reject실시张成福YJ/PIE6/19’12Promotion□物量扩大□新规开拓개선내용BeforeAfter完了개선전:에징룸에온도공제시스템이없음,환경온도가고객님의요구를만족시키지못함.개선후:자동온도공제시스템을설치,온도를자동으로조절.B/I테스트개선과제자동분리기도입Quality□效率向上□工程改善■不良改善□受率向上구분담당자부문기간개선대책Cost□改善VE□购买引下제출인SamsungCustomer5/30’12□AcceptDelivery□纳期缩短□Capa增加■Process改善검토张成福YJ/PIE6/19’12□Reject실시张成福YJ/PIE6/19’12Promotion□物量扩大□新规开拓개선내용BeforeAfter完了개선전:수동으로분리,충격이크기에품질이상이생길우려가있음.개선후:자동분리기를도입.자동화설비도입개선과제자동배송로보트를도입Quality□效率向上□工程改善■不良改善□受率向上구분담당자부문기간개선대책Cost□改善VE□购买引下제출인张成福PIE5/30’12□AcceptDelivery□纳期缩短□Capa增加■Process改善검토程用辉ME6/19’12□Reject실시程用辉ME6/19’12Promotion□物量扩大□新规开拓개선내용BeforeAfter完了개선후:자동배송로보트를도입함으로서효율상승,인력재배치.개선전:솔더시사용하는지그배송전문담당이있어야함.자동화설비도입개선과제완제품운송시스템개선Quality□效率向上□工程改善■不良改善□受率向上구분담당자부문기간개선대책Cost□改善VE□购买引下제출인SamsungCustomer5/30’12□AcceptDelivery□纳期缩短□Capa增加■Process改善검토张成福YJ/PIE6/19’12□Reject실시张成福YJ/PIE6/19’12Promotion□物量扩大□新规开拓개선내용BeforeAfter完了개선전:전통적생산라인은매라인마다완제품포장구역이있기에통로를막는현상이많음.개선후:완제품자동컨베이어벨트설치.자동화설비도입개선과제FT#2자동라인도입Quality□效率向上■工程改善□不良改善□受率向上구분담당자부문기간개선대책Cost□改善VE□购买引下제출인SamsungCustomer5/30’12□AcceptDelivery□纳期缩短□Capa增加■Process改善검토张成福YJ/PIE6/19’12□Reject실시张成福YJ/PIE10/30’12Promotion□物量扩大□新规开拓개선내용BeforeAfter개선전:전통적포장라인은8명이수요,인력낭비..개선후:FT#2자동테스트라인설치완료,적용기종이다양화하지못함,가동율(嫁动率)낮음.(10월말완료될것으로예측)부족사항을촉진과제덮게지그도입Quality□效率向上■工程改善□不良改善□受率向上구분담당자부문기간개선대책Cost□改善VE□购买引下제출인SamsungCustomer5/30’12□AcceptDelivery□纳期缩短□Capa增加■Process改善검토张成福YJ/PIE6/19’12□Reject실시张成福YJ/PIE6/19’12Promotion□物量扩大□新规开拓개선내용BeforeAfter完了개선전:솔더머신에들어가기전덮계지그를사용하지않음,트렌스/E-Cap등본체가높음,부품들뜸현상이있음.개선후:덮계지그를도입,부속품들뜸문제를해결,100%낙하시험을통과.제작공정직통율(直通率)개선과제테스트직통율개선Quality□效率向上■工程改善□不良改善□受率向上구분담당자부문기간개선대책Cost□改善VE□购买引下제출인SamsungCustomer5/30’12□AcceptDelivery□纳期缩短□Capa增加■Process改善검토张成福YJ/PIE6/19’12□Reject실시张成福YJ/PIE6/19’12Promotion□物量扩大□新规开拓개선내용BeforeAfter完了개선전:원래ICT테스트에가성불량이많고테스트시도달율&직통율이80%좌우,전해콘덴서역방향측정이불가능.,개선후:전해콘덴서역방향측정이가능하고,테스트도달율&직통율이95%이상에도달함.E-CapTestPin제작공정직통율(直通率)개선과제마감자재포장개선Quality□效率向上■工程改善□不良改善□受率向上구분담당자부문기간개선대책Cost□改善VE□购买引下제출인金次长Samsung8/6’12□AcceptDelivery□纳期缩短□Capa增加■Process改善검토陈美淩YJ/WH8/10’12□Reject실시陈美淩YJ/WH8/10’12Promotion□物量扩大□新规开拓개선내용BeforeAfter개선전:창고자재발급후마감PCB를비정전비닐주머니로포장.개선후:모든부품을MSD공제기준에따라관리,마감PCB를통일적으로정전비닐주머니로진공포장.完了부품포장방식개선과제마감자재포장개선Quality□效率向上■工程改善□不良改善□受率向上구분담당자부문기간개선대책Cost□改善VE□购买引下제출인金次长Samsung8/6’12□AcceptDelivery□纳期缩短□Capa增加■Process改善검토陈美淩YJ/WH8/10’12□Reject실시陈美淩YJ/WH8/10’12Promotion□物量扩大□新规开拓개선내용BeforeAfter개선전:반도체마감자재를정전비닐주머니로포장했지만진공포장을하지않았음.개선후:모든반도체마감자재를MSD공제기준에따라관리,진공포장함.完了부품포장방식개선과제불량품보관개선Quality□效率向上□工程改善■不良改善□受率向上구분담당자부문기간개선대책Cost□改善VE□购买引下제출인金次长Samsung8/15’12□AcceptDelivery□纳期缩短□Capa增加■Process改善검토陈美淩YJ/WH8/20’12□Reject실시陈美淩YJ/WH8/20’12Promotion□物量扩大□新规开拓개선내용BeforeAfter完了개선전:불량품에대한관리가부족,방습,해빛쪼임등예방조치가없음.개선후:불량품창고를단독으로설치,담당자가독립적으로관리,실물,간판,대장을동시적으로관리.불량품보관개선과제창고6S개선Quality□效率向上□工程改善■불량개선□受率向上구분담당자부문기간개선대책Cost□改善VE□购买引下제출인SamsungCustomer6/27’12□AcceptDelivery□纳期缩短□Capa增加■Process개선검토陈美淩YJ/WH6/30’12□Reject실시陈美淩Yj/WH7/17’12Promotion□物量扩大□新规开拓개선내용BeforeAfter개선전:창고바닥이일반콩크리트바닥이였고어지러워보임.개선후:1.환경보호용녹색잉크로바닥면을바꿈.2.자재구역을재배치.창고6S개선과제장기재고품개선Quality□效率向上□工程改善■不良改善□受率向上구분담당자부문기간개선대책Cost□改善VE□购买引下제출인金次长Samsung8/6’12□AcceptDelivery□纳期缩短□Capa增加■Process改善검토陈美淩YJ/WH8