【正文】 r st a n d i n g / st u d y5 I d e n t i f i ca t i o n amp。 Plan目標(biāo)的設(shè)定和計(jì)劃 ? Determine Goal statement 確定目標(biāo) * [REDUCTION or ZERO] within [3 MONTHS] ? Determine Time Frame of project 確定項(xiàng)目的期限 * From [MONTH] to [MONTH] ? Various items parametrized in Step 2 shall be used Eg: Activities Goal Time Frame 1. No bonding impression Zero in 1 mth 1999 Sep 1 starts 2. With bonding impression Zero in 1 mth 1999 Oct 1 starts 3. Bond impression on die Zero in 1 mth 1999 Nov 1st starts 4. Damaged post Zero in 1 mth 1999 Dec 1st starts 5. Discolored pad 50% reduction in 2 mth 2020 Jan 1st starts ? The plete improvement plan shall be per the normal CI 1pager 1 2 3 Masterplan amp。A d ju s tm e n tM at e ria l D/ Tamp。 Standardization 預(yù)防復(fù)發(fā)和標(biāo)準(zhǔn)化 Step 1 of CI Approach Theme / Reason For Selection選擇的理由 /主題 ? Identify the Theme辨認(rèn) /確認(rèn)主題 * Reduction降低 [or Elimination消除 ] of [Defect Type] in [Product Line] ? State the Reasons For Selection陳述選擇的理由 How does the above affects line performance? * [% OF PROBLEM] affecting [OEE] ? Provide Visual sample of good product with dimension (for VM defects only) 1 0 2 4 6 8 10FI NA L TES TTR IMamp。 Plan目標(biāo)的設(shè)定和計(jì)劃 Outline Of Equipment amp。 jig loss 功能停止 Function stoppage 功能退化 /變質(zhì) Function deterioration 頻率縮小 Reduction in frequency Failure analysis technique WhyWhy PM analysis 設(shè)備使用可靠性的改善 Improvement of equipment usage reliability. 循環(huán)預(yù)防 Prevention of recurrence . 標(biāo)準(zhǔn)回顧 Standard review. ?Industrial Engineering ?QA ?Value Engineering ?Others AM system 橫向的反響 Horizontal replication PM system Office TPM CI項(xiàng)目活動(dòng) Continuous Improvement project activities *Theme selection standard ? Critical items ? Maximum gains ? Can be improved within 3 months QM system 生產(chǎn)活動(dòng)中的損失結(jié)構(gòu)（ 16種主要損失） Loss structure during production activities ( 16 major losses ) 停止損失 編制損失 負(fù)荷工時(shí) 8. 停機(jī)損失 1. 故障損失 2. 作業(yè)準(zhǔn)備損失 3. 工具交換損失 4. 開(kāi)機(jī)啟動(dòng)損失 7. 質(zhì)量缺陷和返工損失 9. 管理?yè)p失 10. 操作動(dòng)作損失 11. 編制損失 12. 物流損失 13. 測(cè)量、調(diào)整損失 14. 能源損失 16. 工具、模具損失 15. 不合格率 作業(yè)總工時(shí) 實(shí)際作業(yè)時(shí)間 有效工作時(shí)間 有價(jià)值的 工作時(shí)間 總工時(shí) 負(fù)荷工時(shí) 運(yùn)行時(shí)間 實(shí)際運(yùn)行時(shí)間 有價(jià)值的運(yùn)行時(shí)間 人的高效化 設(shè)備的高效化 能源 原材料 輸入能源 有效能源 輸入原材料 ( 數(shù)量、重量 ) 認(rèn)證產(chǎn)品的數(shù)量或、和重量 工具 /模具成本 額外工時(shí) 作業(yè)損失工時(shí) 不良損失工時(shí) 計(jì)劃停機(jī) 性能損失 質(zhì)量缺陷損失 質(zhì)量缺陷損失 開(kāi)機(jī)啟動(dòng)損失 切割損失 重量損失 過(guò)剩損失 ( 增加的傭金 ) 工具、模具 來(lái)自生產(chǎn)和維修工具模具的經(jīng)濟(jì)損失 開(kāi)機(jī)啟動(dòng)損失 過(guò)載損失 溫度損失 阻礙設(shè)備效率的8大損失 阻礙 人的效率的5大損失 EQUIPMENT 設(shè)備的 8種主要損失和 OEE的關(guān)系 Relationship between 8 Major Losses on Equipment and Overall Equipment Efficiency. 8 MAJOR LOSSES CALCULATION OF OVERALL EQUIPMENT EFFICIENCY x 100 Loading time downtime Availability = Loading time x 100 460 mins60 mins Availability = 460 mins (Example) = 87% Operating time (Example) Performance = Standard cycle time x Product units processed Performance rate x 100 mins/units x 400 units 400 mins x 100 = 50% rate = Product units processed defect units = (yld) Quality products rate Product units processed x 100 400 units 8 units 400 units x 100 (Example) = 98% Quality products rate 實(shí)際運(yùn)行時(shí)間 性能損失 Perf. Loss 有價(jià)值的 運(yùn)行時(shí)間 質(zhì)量缺 陷損失 Defect Loss 負(fù)荷工時(shí) 運(yùn)行時(shí)間 停止損失 D/Time Loss 總工時(shí) 1)故障損失 Equipment Failure 2)作業(yè)準(zhǔn)備損失 Setup amp。 jig change loss (8) Shut down (SD) loss (13) Measurement amp。 rework loss (2) Setup amp。 Trend Charts * How to handle, in the future, failures that can be dealt with AM [Role of PM] * Identifying recurring failures based on maintenance records Data Trend Chart * Perform permanent fixing of failures which have been dealt with by quick fix OPL’s. Step 2. 失效分析和全面的檢查 Failure analysis and overall inspection * 重新分析經(jīng)常性發(fā)生的失效 Reanalysis of recurrent failures * 新的失效的全面分析 Thorough analysis of new failures [Role of AM] * Analyzing failures considering that they are problems of the manufacturing sector * Repeating whywhy analysis * Inspection of analogous facilities and correction of causes [Role of PM] * Thorough analysis and guidance to AM Activity * Confirmation and correction of repair errors (skill education/training, etc.) 0失效的程序 Program for Zero Failures Cont Step 3. 強(qiáng)力的變質(zhì)的消除和不用照顧的變質(zhì)的糾正 Elimination of forced deterioration and rectification of unattended deterioration [Role of AM] * 通過(guò)清潔尋找最小化的缺陷 Finding minor defects through cleaning * 基本條件的改善 Improvement of basic conditions (Elimination of forced deterioration caused by dirt, suitable oiling, tightening) * Studying use conditions [Role of PM] * Educational guidance regarding minor defects * 使用條件的分類和指導(dǎo) Classification and guidance of use conditions * 消除看不見(jiàn)的強(qiáng)力變質(zhì) Elimination of forced deterioration in unseen portions * 早點(diǎn)被辨認(rèn)的 /識(shí)別的變質(zhì)的糾正 Early rectification of deterioration that have been identified Step 4. 弱點(diǎn)的研究 Study of weak points [Role of AM] *引進(jìn)改善以至于基本條件的維護(hù)將變得更容易 Implementing improvements so that the maintenance of basic conditions will be easier (countermeasures for contamination sources, for hardtoaccess areas) [Role of PM] * 清理和糾正設(shè)計(jì)缺陷 Sorting out and correcting design weak points * 延長(zhǎng)壽命的研究 Study of steps for extending service life * 結(jié)構(gòu)的改善 Structural improvement Step 5. 標(biāo)準(zhǔn)化文件的準(zhǔn)備和控制 Preparation and control of standard documents (including failures involving defects) [Role of AM] * AM標(biāo)準(zhǔn)文件的準(zhǔn)備 Preparation of AM standard documents * 以檢查和變質(zhì)的糾正清單 Check listbased inspection and rectification of deterioration * 通過(guò)總體設(shè)備的檢查來(lái)糾正和觀察故障