喷漆产能提升 DMAIC.pptVIP

* Project Title Painting Line Space Magic Team Leader’s Name CC_Szu; Ken Chang (Reporter) Team Members’ Names Jerry Jan, OK Lee, Tj Zhang, Lucius Zhu, Jeff Liao Location GPS Category Social Environmental Responsibility * Painting Process would make lots of pollution. We should do our best to reduce the raw material. Paint waste residue pool Paint waste residue Raw Painted Material * Very low ratio of actual paint usage (Below 20%). ? Money Loss Environmental Pollution Much waste of paint Paint has high % in JGP BOM cost. Period: ’09Q1-’09Q2 High cost of paint * Please click the picture for VCR Paint Waste! * Waste 1.Paint 2.Space Problem 1st Why 2nd Why 3rd Why Shorten pitch redesign jig 150mm 150mm spindle pitch pitch Ineffective Space Too much invalid space Inappropriate jig and chain design long chain pitch improper jig design * = Paint cover area (Before) Shorten pitch and redesign painting fixture could effectively reduce paint waste (50% max). Circle A Circle B1 Circle B2 How to increase paint usage efficiently？ πR2：2*(π(R /2) 2) = 2：1 Circle A Circle B1+ Circle B2 Paint cover area (After) Comparison of paint cover area R R/2 2D Drawing * Plan Schedule of improvement P D C A Plan: Actual: * How fast can we payback? Implement Saving Analysis Cost to implement USD 32,070 includes Rotation Modification + Spindle + New Jig etc… Improvement scenario USD 20,938 is based on ‘09Q1-’09Q2 actual paint cost of GPS projected 50% paint saving. Payback: 1.5 Day * 1.Modification of paint line Adding spindle support mechanism 150mm 150mm spindle Simple Modification: Only adding support mechanism to the original line chain. Fits all sizes of paint area with good cost control. 150mm * 2.Modification of the rotation Two wheels (pitch in 175 mm) on the triangular shape fixture were not able to ensure the rotation of (new) spindle in middle. Single wheel ensures rotation of eac