TCJ3400 Line Set-up Preparation

12/7 3 day 18/7 1st Line 8 day 24/7 2nd Line 13 day 1/8 3rd Line

No Process Catergory Items Need Prepare 1 MI Tool/jig IC leg bending Jig for U1 IC * check setting 2 MI Tool/jig Component storage bin 3 MI Tool/jig Solder Iron 4 MI Tool/jig Touch up block need lamp 5 MI Tool/jig After dipping cooling fan 6 MI Tool/jig Touch up Jig 7 MI Tool/jig Prevent PCB warpping jig 8 MI Tool/jig IC dispencer jig 9 MI Tool/jig AC contact insertion jig 10 MI Tool/jig Set-up ICT 11 MI Tool/jig Need brush to clean solder ball 12 MI Tool/jig air gun for ICT cleaning process 13 MI Tool/jig D20 prework jig need review ( process & Qty ) 14 Assy Tool/jig PCB breaking jig 15 Assy Tool/jig Dummy Battery 16 Assy Tool/jig Knock test jig 17 Assy Tool/jig Set dismental Jig 18 Assy Tool/jig set up Call lamp 19 Assy Tool/jig nejico with secondary tray 20 Assy Tool/jig Grease dispencer 21 Assy Tool/jig IC writer cycle time high = 19 ~ 22s need 3 units 22 Assy Tool/jig Case screwing process need top cover jig 23 Assy Tool/jig Need battery discharge jig 24 Assy Tool/jig Screwing process request sensor to prevent screw missing 25 Assy Tool/jig Battery A check cycle time high 35 ~ 39S need 4 units 26 MI Set-up MI conveyer & Dipping machine test run 27 MI Set-up Material top up list 28 MI Set-up Line set up & relocate Tuner ICT * air supply 29 MI Set-up Line ESD confirmation 30 MI Set-up Need to know full MI conveyer PCB Qty ? 31 MI Set-up need to buy off WI D20 , C8 , C37 , C2 sub work process 32 MI Set-up ICT pass stamp date code 33 MI Set-up Need review component insertion sequence 34 MI Set-up ICT coverage vs visual check matrix 35 MI Set-up Check flux vs Dipping joint conveyer condition 36 MI Set-up Test MI conveyer speed Slow -OK ? 37 Assy Set-up Extend packing block 38 Assy Set-up Battery A PC hanging block 39 Assy Set-up ESD, power plug point 40 Assy Set-up Control WIP in between process x 3 41 Assy Set-up Hot melt jig & cycle time ?? 8s 42 Assy Set-up Battery B check cycle time high 13 ~ 17S 43 Assy Set-up Appearance check cycle time high 39s 44 MI Quality Model history record list 45 MI Quality U3 add gas hole 46 MI Quality Touch up focus location U3,U4 ,U1,D21,Q22 47 MI Quality New machine Dipping profile 48 MI Quality Target No component lead cutting process 49 MI Quality PCB version matrix ? 50 MI Quality Power transformer packing prefer over turn , easy pick up 51 Assy Quality prevent scratches - No accessory on hand , cosmetic audit

Qty 2 8 3 3 6 3 150 2 3 2 2 2 150 3 14 3 1 4 3 3 2 3 3 3 12

52 53 54 55 56 57 58 59 60 61 62 63 64 65 66

Assy Assy Assy Assy Assy Assy Assy Assy Assy Assy Assy Assy Assy Auto Assy Assy

Quality Quality Quality Quality Quality Quality Quality Quality Tool/jig Quality Quality Quality Quality Quality Quality Quality

Check screw torque Counter to prevent battery A skip process Appearance check template Serial No control method ( lot by lot basic ) Material issueing lot by lot basic AC blade carton label attention by colour Equipment setting & spec indication WI need Quality matrix table ( AC blade ) Use micro sound scope to check foreign material + dummy set Casing rubbing sound Need to prepare difference table AC blade / manual . carton information prefer label type manual prefer change colour possible mix with TAS9700 , template Add glue to reduce Dipping solder short carton packing slot too tight , difficult to take out from slot Bar code scanning system

change oreitation update WI

Preparation

Status OK

ok ok OK ok OK study ok ok

ok ok study OK in progress OK in progress OK OK ok ok ok ok ok ok in progress in progress in progress in progress OK OK pending in progress In progress ok Ng OK in progress ok ok in progress OK

Dept PIC Remark Eng Design limitation 11-Jul PRD Watie 16-Jul PRD JH Tan Eng PRD Razak Eng Eng 12-Jul PRD JH Tan Eng Vincent Eng 16-Jul PRD Watie 16-Jul PRD Watie 10-Jul Eng Takanishi Eng Eng 16-Jul PRD Azri Eng 18-Jul PRD JH Tan 16-Jul PRD Azri 12-Jul PRD Azri 10-Jul Eng Takanishi 10-Jul Eng Vincent 10-Jul Eng Zazli 10-Jul Eng Zazli 10-Jul Eng Zazli 16-Jul PRD/Eng Razak 12-Jul PRD/Eng Watie 16-Jul Eng/PRD Watie 12-Jul PRD Ibrahim 16-Jul PRD Watie 16-Jul PRD Watie 12-Jul PRD Watie 16-Jul PRD Watie 16-Jul PRD Watie 17-Jul PRD Razak 17-Jul PRD Razak 12-Jul PRD Azri 16-Jul PRD / Eng Azri 16-Jul PRD Azri 16-Jul PRD Azri after 3 week Eng Zazli support by nation gate 10-Jul Eng Zazli 10-Jul PRD Azri 16-Jul PRD Watie / Azri Eng 16-Jul PRD Watie 17-Jul PRD Razak 18-Jul PRD Watie PRD/Eng 10-Jul IQC CC Lim 18-Jul PRD Azri

When

ok ok ok ok ok in progress ok ok

18-Jul 18-Jul 16-Jul 16-Jul 16-Jul 16-Jul

ok 2-Jul ok 10-Jul ok 10-Jul Ng 10-Jul test run 10-Jul change oreitation update 10-Jul WI

PRD PRD PRD PC MATC IQC PRD Eng PRD IQC Eng Eng Eng Auto Eng PRD/QC

Azri Azri Azri PS Khoo HH Lee CC Lim Azri

Vincent Teo Zazli Takanishi Govin Vincent

adjust molding parameter

30% PCB will test run add glue process

Critical to Quality Skill Process No Process Skill process 1 MI Touch up Hand insert block check before dipping Visual check inspector 2 Assy IC programming Battery A Attach label Packing PIC Status

ill Process Remark

Model :TCJ3400 2Q Status No Process Model / Version TCJ3400 TCJ3400 TCJ3400 TCJ3400 Cav/panel 6 6 Remark

1 Auto 2 MI 3 Assy

Panel Qty 29 29

Total Qty 174 174 150

Dipping PPM No Location Defect 1 No Solder 2 solder short 3 Pin hole Total

Qty 18 48 0 66

MI ICT Defect Data No LOCATION DEFFECT 1 LED High up 2 LED Reverse 3 C37 Solder Short 4 R25 Shifted 5 U4 Solder Short 6 C8 High up 7 C8 One leg No insert 8 JP1 Missing Total LDR

QTY 1 2 1 1 6 1 1 1 14 8%

Assy Defect Data No LOCATION DEFFECT 1 Case Rubbing Noise 2

QTY 145

3 4 5 6 7 8 Total LDR 145 85%

MI ICT Defect Data No LOCATION DEFFECT 1 LED High up 2 LED Reverse 3 C37 Solder Short 4 R25 Shifted 5 U4 Solder Short 6 C8 High up 7 C8 One leg No insert 8 JP1 Missing Total LDR

QTY 1 2 1 1 6 1 1 1 14 8%

MI Block Check Defect Data No LOCATION DEFFECT QTY 1 C37 Slanting 12 2 D3 High up 4 3 D20 High up 5 4 LED High up 5 5 D20 Slanting 4 6 SA1 High up 1 7 C8 Long lead 7

Total LDR

38 22%

No 1 6 2 3 4 6 7 8 7 2 4 1 5 3 5

Total MI Defect Data LOCATION DEFFECT LED High up C8 High up D3 High up D20 High up LED High up SA1 High up C8 Long lead JP1 Missing C8 One leg No insert LED Reverse R25 Shifted C37 Slanting D20 Slanting C37 Solder Short U4 Solder Short

QTY 1 1 4 5 5 1 7 1 1 2 1 12 4 1 6

One leg Shifted No insert Missing 2% High up 17 2% Reverse 2% 4% Slanting 16

17

Long lead Long lead 13%

Solder Short Reverse Shifted Solder Missing Short One leg No insert 13%

7 1 1 2 1 16 7

Slanting 31%

7 7 2 High up 1 33% 1 1

LOCATION C37 C8 U4 D20 LED D3 D20 LED LED C8 SA1 JP1 C8 R25 C37

DEFFECT Slanting Long lead Solder Short High up High up High up Slanting Reverse High up High up High up Missing One leg No insert Shifted Solder Short

QTY 12 7 6 5 5 4 4 2 1 1 1 1 1 1 1

Assy Defect Data No LOCATION DEFFECT 1 Case Rubbing Noise 2 3 4 5 6 7 8 Total LDR

QTY 145

No 1 2 3 4 5 6 7 8

Assy Visual Check Defect Data LOCATION DEFFECT QTY LED slanting 35 C8 long lead 9 C8 high up 1 C1 high up 4 C37 slanting 2 LED high up 1 N pin hole 1 C2 high up 2 Total LDR 55 32%

Repair 10

145 85%

No 1 6 2 3 4 6 7 8 7 2 4 1 5 3 5

Total MI Defect Data LOCATION DEFFECT LED slanting C37 slanting N pin hole C8 long lead C8 high up C1 high up LED high up C2 high up

QTY 35 2 1 9 1 4 1 2

pin hole

37 1 9 8

2% Slanting 0% Long lead High up High up 15% pin hole Long lead 16%

0%

0%

37 9 0% 8 1

Slanting 67%

LOCATION LED C8 C1 C37 C2 N C8 LED

DEFFECT slanting long lead high up slanting high up pin hole high up high up

QTY 35 9 4 2 2 1 1 1

Model :TCJ3400 Dipping PPM No Indicator Defect 1 No Solder 2 solder short 3 Pin hole Qty 18 48 0
propose to add glue propose to add gas hole

MODEL TCJ3400 CYCLE TIME (SEC)

LINE ASSY

O/P TARGET 170

ENGINEERING PROCESS VS TIME STUDY LINE BALANCING/PROCESS STANDARD TIME/DAILY OUTPUT

CYCLE TIME 190.59 HEADCOUNT 10 DATE BALANCING EFFICIENCY =
27.06.2013

TOTAL PROCESS TIME 204 x 100 % = 39 x 10 MAX TIME x NO. OF OPRS Remark

52.3 %

40

35 30 25
20

output= 1200

15 10 5 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

target = 7 sec

TACT

TIME

9 Visual Inspection PCBA 21 IC Program & Powerware(Tester:13.12s) 19 C'bine PCB to L/case & Apply grease. 17 Combine cases & Screwing. 17 Knock test & Hipot(Tester:5.41s) 11 Battery A(Tester:26.00s) 35 Battery B(Tester:7.38s) 13 Appearance check 39 Label attach 10 Packing 13

204

PROCESS:INSERTION ~ PACKING CYCLE TIME AVERAGE 20.4 SEC ACTION TAKEN

DESCRIPTION

Breaking

JOB

max tact time calculation Daily Ouput (9.00hrs): 808 pcs. Hourly Output: 92.3 pcs

productivity / pass yield *if 95% yield: 767 pcs Hourly Output: 87.7 pcs

Thin Thin

NAME

NO. EMP.

Suriani

Atikah

Yahya

REV : 0

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

1 2 3 4 5

Vijaya

Milan

Fatin

Mimi

Borj

Arsi

APPROVED

CHECKED

PREPARED

KAGA COMPONENTS (M) SDN BHD Engineering / QA Comment Sheet Problem Statement
1

Model :TCJ3400 Customer :Kaga Root Cause

Event :PP Date :14.5.13 Proposal Action PIC / Date

A,B,C
study

D20 slanting

A,B,C

U1 need to do prework IC lead bending by jig Prefer widen U1 location hole follow U1

productivity loss prework IC ( bend IC lead )

Widen the U1 PCB insertion position hole

dimension
3

A,B,C
propose to add glue in between U2 lead

U2 solder short

4 5

A,B,C
propose to add glue in between C37 lead

C37 solder short

6 4 5

A,B,C
propose to add gas hole

U3 solder short

New & Critical Model event on Line

Model TCJ3400 TCJ3400 Sec TAS TAS PRD MI ASSY Event N N Qty 69000 69000

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
1.2 1.8 1.2 2.4 2.4 3.6 4.8 1.8 1.8 3.6 4.2 6 6 7.2 9 9 9 9 4.8 5.4 6.6 7.8 7.8

Output 1200 1800 2400 3000 3600 4000

W/H ( S ) 32400 32400 32400 32400 32400 32400

Cycle time 10% loss 27 24.3 18 16.2 13.5 12.15 10.8 9.72 9 8.1 8.1 7.29

30 31
6.6 9 6

MODEL TCJ3400 CYCLE TIME (SEC)

LINE PCBA

O/P TARGET 170

ENGINEERING PROCESS VS TIME STUDY LINE BALANCING/PROCESS STANDARD TIME/DAILY OUTPUT

CYCLE TIME 190.59 HEADCOUNT 17 DATE BALANCING EFFICIENCY =
26.06.2013

TOTAL PROCESS TIME 113.11 x 100 % = 29 x 17 MAX TIME x NO. OF OPRS Remark

22.9 %

40

35 30 25
20

15 10 5 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

target = 7 sec

Pre-inspection before dipping

ICT (Tester=2.42s)

Insert AC Contact

113.11

3 3 3 4 4 3 4 3 3 4 3 3 4 29 8 5.7 26.41

TACT

TIME

PROCESS:INSERTION ~ PACKING CYCLE TIME AVERAGE 6.65 SEC ACTION TAKEN

DESCRIPTION

Nwe Htay

Suhaida

NAME

Norlina

Visual inspection

Insert CN1

Insert D20

Insert SA1

Insert C37

Touch Up

Insert U1

Insert U2

Insert C1

Insert C2

Insert C8

Insert T1

Insert F1

Insert L1

JOB

max tact time calculation Daily Ouput (9.00hrs): 1086 pcs. Hourly Output: 124 pcs

productivity / pass yield *if 95% yield: 1032 pcs Hourly Output: 118 pcs

NO. EMP.

Surtina

Bhakta

Rabiul

Shima

Zaiton

Vijaya

Zaida

Lina

Siti

REV : 0

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 26

1 2 3 4 5 6

Syikin

Maria

Firna

Tina

Suri

APPROVED

CHECKED

PREPARED

MODEL: TCJ3400 JUMP LIST STEP 6 7 8 75 88 89 100 101 138 139 140 144 154 PARTS NAME U1 5-6 U1 6-7 U1 7-8 C5*/ C28*/ C29*/ C40*/ C41*/ U1 G-6 U1 G-7 U1 G-8 U3* G-2 U4* G-9 LO ACT UN STD UN MEAS UN RO,CO UN MD -R H-LIM UN L-LIM UN HPIN LPIN C2 10 o 10 o 14 0 10 % -10 % 50 0 C2 10 o 10 o 14 0 10 % -10 % 0 51 C2 10 o 10 o 14 0 10 % -10 % 51 51 C2 22 pF 22 pF 7 0 20 % -20 % 51 50 C1 100 nF 100 nF 7 0 20 % -20 % 42 43 C1 100 nF 100 nF 7 0 20 % -20 % 9 42 C1 100 nF 100 nF 7 0 20 % -20 % 42 10 C1 100 nF 100 nF 7 0 20 % -20 % 42 10 C2 1V 0.75 V 10 -4 20 % -20 % 51 0 C2 1V 0.75 V 10 -4 20 % -20 % 51 51 C2 1V 0.75 V 10 -4 20 % -20 % 51 51 C1 1V 0.75 V 10 -4 20 % -20 % 42 42 C1 1V 0.75 V 10 -4 20 % -20 % 42 42 JFHPA 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 COMMENTS NO TEST POINT NO TEST POINT SAME POINT //C2 //C37 //C40/C41/U3/U4 /C29/C41/U3/U4 /C29/C40/U3/U4 NO TEST POINT SAME POINT SAME POINT SAME POINT SAME POINT

Model No : TCJ3400

QTY No. COMPONENT 1 RESISTOR 2 CAPACITOR 3 INDUCTOR /TRANSFORMER 4 DIODE /ZD/LED 5 TRANSISTOR 6 IC 7 JUMPER 8 FUSE 9 PHOTO COUPLER 10 VARISTOR 11 OVERALL 85 AT PCB 33 29 2 7 3 3 5 1 1 1

QTY TESTED 33 24 2 7 3 3 5 1 1 1

QTY JUMPED 0 5 0 0 0 0 0 0 0 0

TEST % 100 83 100 100 100 100 100 100 100 100

80

94%

TCJ3400 PP3 problem facing review No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Process MI MI MI MI MI MI Assy Assy Assy Assy Assy Assy Assy Assy Assy Assy Assy Assy Assy Auto Items Need Prepare U1 Ic need bending process ICT L1 need to check value Power transformer packing prefer over turn , easy pick up auto punch LED request extend lead length C8 request purchase standard part D20 prework jig need review ( process & Qty ) IC writer cycle time high = 19 ~ 22s need 3 units Case screwing process need top cover jig carton packing slot too tight , difficult to take out from slot Need battery discharge jig Screwing process request sensor to prevent screw missing Hot melt jig & cycle time ?? 8s Casing rubbing sound Need to prepare difference table AC blade / manual . Battery A check cycle time high 35 ~ 39S need 4 units Battery B check cycle time high 13 ~ 17S Appearance check cycle time high 39s carton information prefer label type manual prefer change colour possible mix with TAS9700 Add glue to reduce Dipping solder short Teo 10-Jul Takanishi 10-Jul Takanishi 10-Jul Vincent 10-Jul Vincent 10-Jul Zazli 10-Jul Zazli after 3 week Zazli 2-Jul Vincent 10-Jul Teo 10-Jul Zazli 10-Jul Zazli 10-Jul Azri 10-Jul Zazli 10-Jul Takanishi 10-Jul Govin When PIC

10-Jul Badri 10-Jul CC Lim

review Status NC Ok in progress NC NC study 2 unit study in progress OK in progress OK change In progress OK study In progress study study test run 30% PCB will test run add glue process support by nation gate adjust molding parameter machine limitation Need prework jig & update WI Remark Design limitation

TCJ3400
F1 C1 SA1 L1 C2 C7 U1 U2 CN1 C8 C37 N T1 D20 C23 L

No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Location CN1 C37 C8 U2 U1 C7 C2 L1 C1 T1 D20 F1 C23 SA1 L / N plate Remark o x

Wrong value Reverse x x o o o x x o x x o o o o x x o o x x o o o x o o o x x x

High up o o o o o o o o o o o o o o o

Missing o o o o o o o o o o o o o o o

One leg Not insert o o o o o o o o o o o o o o o

Need prework Cut lead x x o o o o x x o x o o o o x x o o x x x o o o o o o o x x

ICT

Assy

Old PCB

possible happen not possible happen

* *

Need clincing jig to prevent high up Need prevent PCB warping jig to reduce dipping PPM

F1 SA1 Old PCB New PCB