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AGENDA
Lean Six Sigma Background
D-M-A-I-C Improvement Process Methodology
Case Study
Define Phase
Measure Phase
Analyze Phase
Improve Phase
Control Phase
Summary and Conclusions
A Look Forward
Acknowledgement
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is D-M-A-I-C?
M EASURE
baseline the process and obtain data to quantify process performance. Measure
the system analysis and Value Chain Analyses (Yield, Cycle Time).
A NALYZE
analyze data to identify tangible root causes of defects. Identify sources of
variation. Screen and validate potential causes, and identify waste.
analyze data to identify tangible root causes of defects. Identify sources of variation.
Screen and validate potential causes, and identify waste.
I MPROVE
brainstorm on solutions and determine variable relationship Y = f(X). Confirm
results and validate improvements. Reduce Waste and streamlining Processes.
C ONTROL
develop control plan and implement process controls. Lesson learned and project
closure.
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Figure 1: Reported
DEFINE Phase
Define the problem by starting a Project Charter. Project Charter included the
project scope and project objective. The scope will be the process framework and
description and end to end process. Then work on a SIPOC (Supplier Inputs Process
Outputs Customers). Start and end boundary for end to end process.
Project Charter
SIPOC
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MEASURE Phase
Measure the performance by including these steps. Process and functional
deployment map, value stream mapping, identify improvement areas, data collection
plan, Gage R&R study (attribute agreement analysis).
MEASURE Phase
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MEASURE Phase
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MEASURE Phase
ICT
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MEASURE Phase
FCT
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Analyze Phase
Identify opportunities for Improvement at ICT
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Analyze Phase
Identify possible root causes at ICT using Fishbone diagram
Analyze Phase
Identify possible root causes at FCT using Fishbone diagram
Analyze Phase
Validate potential causes for ICT low FPY
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Improve Phase
DOE for solder paste printing to improve ICT FPY
Improve Phase
Solder paste printing before & after the DOE study
Improve Phase
Effectiveness of the FCT process redesign solution
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Control Phase
Control the performance by integrating and managing control solutions &
implementation plan through
Process control system template for solder paste printing at SMT and for FCT
I-MR chart for solder paste printing at SMT
Perform U-chart for IB external wrap failure at FCT
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A Look Forward
As globalization progresses, there are areas we can improve in applying Lean Six
Sigma in Manufacturing. As such, continuous improvement through Lean Six Sigma
methodology is a necessary approach that should be ingrained in every corporate
vision and culture to achieve outstanding operational excellence.
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ACKNOWLEDGEMENTS
The authors would like to thank the following people for their help and support
Marie Cole
Hock Keng Neo
Lee Leng Tey
Kenneth EH Koh
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Matt Kelly
Chin Meng Tan
Stephen SL Chong
Justin Gilbert
Casey KC Ng
Kok Yin Loh
Questions ?
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