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1、Thru RTY Innovation,Achieve,10 million per year,LG Electronics/Digital Appliance Company LGETA MWO,http:/,Vision,12.5,11.8,10,1,10.0,9.8,(04 Target),(03,Million),TA(10.0),TA(11.1),Global No.1 MWO Division(05 Sales:M$385；Profit:8%),China Market Top 1(05 China M/S:45%),Cost Competition,Before,2005,Now
2、,As the basement of Profit Turnaround,Fast Innovation,Fast Growth,MWO Maker Benchmarking,Vision,Vision,1/19,Big Y Issue,7.1,10.0,02,03,CMO,Productivity loss,Portfolio by Category,High,Low,Price,Profit,High,Quality loss,Parts loss,Fast Growth,New MDL,Accelerate tool shift(0.7 1.8),Shorten the develop
3、ment period,Increasing number of parts,M unit/year,2/19,Input,Output,Process,Assy Line,Press,Welding,Painting,Purchase,IQC,OQC,PCB,Supplier,Customer,Logistics system(Material,Product)Parts loss control Inspection System Box quality control,Round Cavity strength PCB ICT FCT control Powder quality Gap
4、 defect.Product and Quality Strategy IR sensor quality Press line system,Quick response system Outgoing Inspection system Material storage system,Main Issue,Big Y Issue,3/19,Define,Measure,Analysis,Improve,Control,Supplier,IQC,Painting,PCB,Assy,OQC,Customer,Better logistics,Worst logistics,IQC,Waiti
5、ng for?,Stock,Product stock,Assy line,Painting line,PCB line,Neck Point,Plan change Everyday Stock is not enough Elevator is not enough Packing Time too long Broken Box Check time conflict Poor loading method,Logistics improvement,Best practice-1,4/19,Vendor and supervisor meeting,Define,Measure,Ana
6、lysis,Improve,Control,Logistics improvement,Best practice-1,Supplier,IQC,Painting,PCB,Assy,OQC,Customer,5/19,Best practice-1,Define,Measure,Analysis,Improve,Control,Waiting for,Ppk=-1.01,Miscellaneous ratio,EA/h,One-way ANOVA:make invoice,invoice,inspection,check,stock,recoverAnalysis of VarianceSou
7、rce DF SS MS F PFactor 5 908047 181609 70.14 0.000Error 138 357333 2589Total 143 1265379 Individual 95%CIs For Mean Based on Pooled StDevLevel N Mean StDev-+-+-+-+-make inv 24 14.70 5.71(-*-)invoice 24 21.98 10.96(-*-)inspecti 24 15.06 2.41(-*-)check 24 26.75 15.64(-*-)stock 24 229.85 122.93(-*-)rec
8、over 24 8.27 4.47(-*-)-+-+-+-+-Pooled StDev=50.89 0 80 160 240,Make invoice,Inspect,Stock,Recover part,Check unload,Invoice check,Logistics improvement,Supplier,IQC,Painting,PCB,Assy,OQC,Customer,6/19,7/19,Define,Measure,Analysis,Improve,Control,IQC,Stock,Product stock,Assy line,Painting line,PCB li
9、ne,Press stock,Support time control,Load method,Box stock,Best practice-1,Logistics improvement,Supplier,IQC,Painting,PCB,Assy,OQC,Customer,Best Practice 2Assy RTY innovation,Define,Measure,Analysis,Improve,Control,Forget self check,Latch Adjust,D/Frame,Latch,L/Board,Cavity,Man,Old or new,Method,Mou
10、ld aging,Total inspection,burr,Machine,Parameter injection,Material,Gage aging,The way,PPK=0.06,Latch 3 mould is CTQ,One-way ANOVA:latch1,latch2,latch3,latch4Analysis of VarianceSource DF SS MS F PFactor 3 53.18 17.73 3.40 0.020Error 116 605.11 5.22Total 119 658.30 Individual 95%CIs For Mean Based o
11、n Pooled StDevLevel N Mean StDev-+-+-+-+-latch1 30 100.92 0.94(-*-)latch2 30 100.92 0.76(-*-)latch3 30 102.27 4.30(-*-)latch4 30 100.52 0.95(-*-)-+-+-+-+-Pooled StDev=2.28 100.0 101.0 102.0 103.0,Latch adjustment improvement,Best practice-2,Supplier,IQC,Painting,PCB,Assy,OQC,Customer,8/19,Define,Mea
12、sure,Analysis,Improve,Control,Regression Analysis:time versus latch b,latch b-p,latch b-l,latchThe regression equation istime=-0.24+0.0176 latch b+0.0920 latch b-p+0.278 latch b-l-0.0148 latchPredictor Coef SE Coef T PConstant-0.243 3.481-0.07 0.945latch b 0.01756 0.03172 0.55 0.585latch b-l 0.09197
13、 0.02284 4.03 0.000latch b-p 0.27811 0.02761 10.07 0.000latch-0.01481 0.02400-0.62 0.543S=0.02795 R-Sq=81.9%R-Sq(adj)=79.0%,Regression Analysis:time versus latch b-p,latch b-lThe regression equation istime=0.019+0.0948 latch b-p+0.278 latch b-lPredictor Coef SE Coef T PConstant 0.0192 0.6785 0.03 0.
14、978latch b-0.09475 0.02186 4.33 0.000latch b-0.27777 0.02589 10.73 0.000S=0.02717 R-Sq=81.6%R-Sq(adj)=80.2%,PPK=2.19,Pooling,Latch adjustment improvement,Best practice-2,Supplier,IQC,Painting,PCB,Assy,OQC,Customer,9/19,Define,Measure,Analysis,Improve,Control,Past film,Hold,Put film,Put,Take off,Pres
15、s film,Hold plate,Turn around,Hang,2.8,0.9,1.0,1.0,1.8,1.3,0.7,1.0,2.0,Sec.,03,2.3,0.8,0.8,0.9,1.7,1.2,0.7,0.8,1.1,Ppk=-0.31,02,Chi-Sq=5.692+0.008+0.011+0.000+0.077+0.000+6.151+0.008+2.628+0.003+1.681+0.002+5.037+0.007+0.001+0.000+1.080+0.001+0.699+0.001+0.001+0.000=23.089DF=10,P-Value=0.010,Scratch
16、 by Model Analysis,Chi-Square Test:Defect2,Total2Expected counts are printed below observed counts Defect2 Total2 Total 1 9 14783 14792 19.49 14772.51 2 5 14783 14788 19.48 14768.52 3 2 14784 14786 19.48 14766.52 4 62 14784 14846 19.56 14826.44Total 78 59134 59212,Chi-Sq=5.642+0.007+10.764+0.014+15.
17、683+0.021+92.114+0.122=124.367DF=3,P-Value=0.000,Scratch by Vendor Analysis,Best practice-2,Supplier,IQC,Painting,PCB,Assy,OQC,Customer,Door assy process improvement,10/19,Define,Measure,Analysis,Improve,Control,Door assy process improvement,Best practice-2,Supplier,IQC,Painting,PCB,Assy,OQC,Custome
18、r,11/19,Define,Measure,Analysis,Improve,Control,Standard work,VCD training,Standard line,Standard sample,Other line,Training Process,Training for new employee When line stop,training Supervisor inspection inspect oneself.,VOC research,Standard modify,Process training,Supplier,IQC,Painting,PCB,Assy,O
19、QC,Customer,Best practice-2,12/19,Define,Measure,Analysis,Improve,Control,Painting line improvement,Powder differentSlow line speedPainting robot defectProgram different,New model new Problems,Painting condition,Powder condition,Supplier,IQC,Painting,PCB,Assy,OQC,Customer,Best practice-3,13/19,Estim
20、ated Regression Coefficients for cost_1 Term Coef SE Coef T PConstant 0.498799 1.06587 0.468 0.045PG 0.016906 0.08130 0.208 0.037PSP 0.016195 0.09905 0.164 0.002voltage 0.003204 0.00554 0.579 0.029S=1.1027 R-Sq=98.2%R-Sq(adj)=92.6%,14/19,Analysis of Variance for intencitySource DF Seq SS Adj SS Adj
21、MS F PRegression 10 399.405 399.4050 39.94050 16.54 0.003 Linear 5 370.783 42.4636 8.49272 3.52 0.097 Interaction 5 28.623 28.6225 5.72450 2.37 0.183Residual Error 5 12.073 12.0725 2.41450 Total 15 411.478,Define,Measure,Analysis,Improve,Control,Ppk=0.37,Estimated Regression Coefficients for intenci
22、tyTerm Coef SE Coef T PConstant 0.525 34.493 0.015 0.088voltage 0.045 0.105 0.432 0.042PG-9.175 5.124-1.791 0.033PSP-7.250 5.298-1.368 0.029time 16.875 25.325 0.666 0.535dianji 627.500 506.498 1.239 0.070voltage*PG 0.034 0.016 2.188 0.080voltage*PSP 0.026 0.016 1.673 0.155voltage*time-0.065 0.078-0.
23、837 0.441voltage*dianji-2.700 1.554-1.738 0.043PG*PSP 0.288 0.388 0.740 0.046S=1.554 R-Sq=97.1%R-Sq(adj)=91.2%,Pooling,Ppk=1.19,Voltage,PG,PSP,02.12,03.6,3.6,2.75,21%,RTYz,Painting line improvement,Supplier,IQC,Painting,PCB,Assy,OQC,Customer,Best practice-3,Best Practice 4PCB line improvement,Define
24、,Measure,Analysis,Improve,Control,PCB line improvement,Ppk=-0.74,LEAD,Head Adjust,ANVIL high,(Head),1.2+0.5,1.5+0.1,Spec,Pre _CTQ,Knife,CUTTER,Part,Eyelet,5mm,10mm,RT,ICT,MANInsert,AutoSoldering,ICT,LED SOLDER,FCT,C/P serve,PCB serve,K/M past,SCREW,FCT,Auto Insert,Solder,Assemblage,Supplier,IQC,Pain
25、ting,PCB,Assy,OQC,Customer,Best practice-4,15/19,16/19,Define,Measure,Analysis,Improve,Control,Term Coef SE Coef T PConstant-325.8 534.135-0.610 0.006cutter 44.4 84.500 0.525 0.001anvil-11.6 11.390-1.017 0.033head 77.4 57.426 1.347 0.208cutter*counter-1.6 3.369-0.467 0.651anvil*anvil-0.3 0.135-2.408
26、 0.037head*head-8.1 3.369-2.408 0.037cutter*anvil 1.0 0.904 1.051 0.318cutter*head-4.3 4.521-0.940 0.369anvil*head 0.4 0.904 0.442 0.668S=0.1279 R-Sq=83.0%R-Sq(adj)=79.7%,Finding Optimized Condition,Ppk=-0.74,Ppk=2.17,Before,After,Cutter Anvil Head 12.5 1.2 1.5,PCB line improvement,Supplier,IQC,Pain
27、ting,PCB,Assy,OQC,Customer,Best practice-4,Best Practice 5Part quality innovation,10 million TDR Activity,Define,Measure,Analysis,Improve,Control,Vendor parts improvement,Vendor TDR meeting,Before,Now,Quality?,Supplier,IQC,Painting,PCB,Assy,OQC,Customer,Best practice-5,17/19,System Control,Control,Lead time,RTYq,Bar cord system,Feb.,March.,Apr.,May.,Jun.,122,96,83,64,32,Quality Control,RTY,Feb.,March.,Apr.,May.,Jun.,3254,2243,514,1067,1939,PPM,Min.,3.51,18/19,Future Plan,Yft1,Yft2,Yft3,Yft4,Yft5,Yft6,Yft1,Yft2,Yft3,Yft4,DMS Building,19/19,Fast Growth Fast Innovation,Thank You,LGETA MWO,
