6sigma Project Report

IMPROVE- Improvement Plan
Improvement plan:
Root Cause
Lack of usual component statistics document Cable selection depend on experience Lack of crimping list model Lack of DVP model
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D M
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P-MAP
After improvement, we added some critical inputs to steps, which will help reduce the overall lead time.
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IMPROVE- IMR Chart (Before/After)
Failure Effects
SEV
OCC
DET
RPN
Cause
Controls
Actions
Component selection
Cost increase
9
Cable selection depend on experience Lack of usual component statistics document
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12
D M A
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C
Improve Design Process
※ Crimping List
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13
D M A
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Improve Design Process
※ Design Validation Plan
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8
Design cable selection tool
7
504
According to cable selection tool, select suitable cable diameter Select component from BOD,and update BOD regularly
Component selection
8
Lack of crimping list model
8
Build Crimping list model
7
448
According to crimping list model complete crimping list.
Design Valiadtion Plan
9
Lack of DVP model
7
Build DVP model
7
441
Write DVP refer to DVP model and then get customer approval Take unique input document format other engineer check 2 times request customer double check input data.
45
5
SE drawing error
Modify Drawing
3D harness arrange
3
Customer arround date unfullness
4
Duble check data with customer
4
48
Security Classification
8
MEASURE-PARETO
Compare Current Status and Improved Status
Improved level is 7.08 days.
Conclusion: Generally, HV harness design lead time reduced 7 days, which is 11.6% reduction.
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Contract Sheet
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3
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Problem Description and Background
Background:
– HV Harness conceptual design includes Electrical Schematic Design, Components Selection, 3D & 2D Harness Drawing Design, BOM & Chart, Crimping list, and Design Validation Plan. When a certain business opportunity comes, all above need to be prepared and sent to SAL, PUR, IE, etc. for quotation and prototype.
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4
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Initial Lead Time
Current level is 60.75 days.
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5
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SIPOC
Y
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6
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P-MAP
These 3 steps greatly impact the total HV harness design lead time, which will be our focus.
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Control Plan
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19
SAVING
The improved process of save cost is as below:
Hybrid average salary:1000 $/month Work time:176h/month Hybrid engineer quantity:11 Each step save time as follow: Technical Proposal:2day BOM:0.5day Chart:0.5day Crimping list:0.5day Drawing&3D:2day DVP:1.5day Total:7days Save cost: $ 318.2 Hybrid average salary:$1000 /month Work time:176h Hybrid Project number:33
Draw schematic
Schematic error
Customer input error 2D drawing error Harness interfere with other component
4
3
Double check customer input
Double check
4
3
80
Securit- Auto Program Introduction
Auto Test Program Measurement Program Interface – one setup , four test items
Conclusion: Using this auto test program, we can do USB RF four test items simultaneously, and achieve auto measure and saving test data.
Security Classification
7
ANALYZE-FMEA
Failure Modes and Effects Analysis ( FMEA )
Process Stephe Failure Mode
Cable design diameter bigger than ausual requried Component unusual
14
D M A
I
C
Improve Design Process
※ Bill of design --- Cable
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15
D M A
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C
Improve Design Process
※ Fuse & Cable Selection Tool
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Problem Statement:
– Now many documents and drawings need to be prepared for quotation, and more and more business opportunity will be come in future, so it is urgent to optimize the conceptual design process and shorten lead time.
purchase difficultly
8
7
Build BOD
8
448
Select crimping requirement
Crimping requirement Lead time to and test long mothod various DVP can't satisfy to customer DV test standard and parameter various