Phasefourpresentation.pptx

Belton ConfidentialControl Phase30-Jul-03Control phaseProject DescriptionProject Title:The coil resistance of X15-150Green Belt:JB ZhuDepartment:BEL MEChampion/Manager:BH Koh/KS ParkEnd customer:SeagateControl phaseProject DescriptionProblem Statement:The resistance of X15-150 coil is close to upper limit per winding result,and customer complained three times the resistance out spec.days.Goal/Objective Statement:Currently,the resistance of X15-150LP coil is close to upper limit.But,since we built small quantity samples every lot,so the readings of resistance are consistent and the Cpk is good.So I will study the mean at the first stage instead of the Cpk,the target is to make the mean of each winding match the spec.mean.For long term target,it is to make the Ppk greater than 1.5 and the resistance match the spec.mean.Other Benefits:1.Improve the DPPM and prevent scrap.2.Improve the process capability and eliminate customer complain.Control phaseTeam MemberNameOrganizationJB ZhuME Actuator and coil-Leader/Data analysisCL YangME Actuator-Actuator MEJX GuoME Actuator-Coil PostZhi Ping LiME Coil-Coil windingLY YangME Coil-MeasurementControl phaseUpdate Trend ChartBelow is the latest trend chart.This trend chart is based on the coils are all wound by 0.201mm wire.The target of last time is 5.814,per the baseline which is 5.863 this time,the target does not met.Per this trend chart,update the target as 5.82.BaselineTargetEntitlementControl phaseProject TimelinePhaseDeliverablesPlan Due DateActual Complete DateDTrend Chart April 2,2003April 04,2003+MFishboneMarch 31,2003March 29,2003GR&RApril 01,2003April 02,2003FMEAApril 08,2003April 07,2003+ATrend ChartApril 30,2003May 5,2003Multi-VariMay 7,2003May 10,2003Hypothesis TestsMay 7,2003May 10,2003ANOVAMay 8,2003May 12,2003+IDOE PlanJune 16,2003June 16,2003DOE AnalysisJune 23,2003June 23,2003Revise SettingTBD+CUpdate Trend ChartJuly 28,2003July 28,2003Process Control PlansJuly 29,2003July 29,2003+Control phaseImprove phase resultRecall the result from Improve PhaseThe KPIVs found from Improve phase are:Coil ID&Winding Tension Revised setting0.201mm wire with 2.5N winding tension Reconfirmation run result.Because we have no 0.200 mm wire on hand so we use 0.201mm wire,and the winding tension is 2.5N to reconfirm the setting.5.8013-0.2270*0.201+0.119*2.5-0.0167*0.201*2.5=6.044But the actual resistance is 5.689,that suggest the equation is not adequate,there may be other noise factor which will also affect on the coil resistance.Control phaseProcess Control PlanSince number of turns is fixed factor,and the wire ID is determined per each lot wire,so the winding tension is the main KPIV will be monitored in future.Current,the technician tests the winding tension every shift.For wire replacement and program adjustment,will also test the winding tension.Current does not monitor the wire ID per each spool,there is just IQC audit each lot.The technician who is responsible for the product will also responsible for the monitoring and take action.Control phaseControl ChartControl phaseConclusionPer the control chart at last page,the UCL is 5.901 and the LCL is 5.826.The coil resistance are all measured at coil winding level.Because the coil leads cant be cut at the right length at coil winding level,there must remain about 20mm for each lead for coil post process convenience.So the actual resistance will be less than the measured value.Will consider to have a compensation next time when make the trend chart.Control phaseIssues/BarriersThe experiments are limited by the wire,the special ID wire must be ordered specially,so the cost will increase largely.And the lead time will be too long.Each special build need more than 3 hours including the program setup.That will occupy lots of machine time that may conflict with the mass production plan.Control phase