Some real world examples of issues faced and results achieved in Real-timeSPC software implementation in Malaysia.
This manufacturer produces Pressure Gauges:
- Key Process : Assembly Process
- Most components for the Pressure Gauges are purchased from suppliers
Before the Implementation of the Real-time QC and SPC Software, the key QC Problems faced by this manufacturers are:
- Components that do not meet specifications leak to the Assembly Process and cause downtime in the Assembly Process
- In-coming QC Inspection requires a lot of manpower and time due to the huge amount of components to inspect and the tediousness of the manual QC Inspection process. This makes the In-coming QC Inspection ineffective, unreliable and slow.
- Management does not have orderly In-coming QC Information to pinpoint to their component suppliers
The Real-time QC and SPC Software implemented in this factory is designed with the following workflow:
- The gauges (calipers, height-gauge, micrometers, weight scales) and a Foot Switch are connected to the “Data Collection Computers” of the Real-time QC and SPC Software
- The QC Inspector will measure the In-coming components using the gauges and the data is transferred to the Real-time QC and SPC Software directly by pressing the Foot Switch.
- Any Out-Of-Control or Out-Of-Specification occurrance will be highlighted in RED to the QC Inspector on the “Data Collection Computers”
- After the QC Inspection, the reports and the relevant charts for the Inspection (e.g. Checksheet, Control Charts, Histogram, etc) is automatically generated.
After Implementation of the Real-time QC and SPC Software, the results achieved by the manufacturer are:
- The In-coming QC Inspection is very responsive and leaking of defective components to the Assembly Processes is reduced significantly
- The Manpower required for In-coming QC Inspection is reduced significantly
- Management can easily provide reports to the component suppliers to inform the the quality of the components supplied.
A Hard Disk Cover manufacturer, in which the key process is Machining uses Real-time SPC Software to reduce their On-Hold Items from 14% to 2.5% in less than 6 months.
Case Study: Reduce On-Hold Items (OHI) from 14% to 2.5%
In the Real-time SPC Software implementation in this factory.
- A product (hard disk cover) is sampled every hour and sent to the QC Laboratory for testing.
- In the QC Lab, CMMs (Coordinate Measurement Machines) are used to measure the Product Sample.
- Immediate after all parameters for the Sample are measured by the CMM, the data is automatically transferred through LAN to the Real-time SPC Software Server.
- The Real-time SPC Software Server will analyze the data sent to it from the CMM to check for Out-Of-Specifications and Out-Of-Control Conditions.
- When the Real-time SPC Software Server detects any Out-Of-Specifications and Out-Of-Control Conditions, it will send an On-screen Alert to the Monitoring PCs that are located in the Production Area informing on the parameters which are Out-Of-Specifications or Out-Of-Control and the Machine that manufactures the Product Sample
- Whenever the Technicians and Engineers in the Production see An On-Screen Alert on the Monitoring PCs, they will investigate the problem at the machine.
Within 3 months of the implementation of the Real-time SPC Software, the factory achieves the following results:
- On-Hold Items reduce from 14% to 2.5%
- Rejects reduce from 5% to 0.3%
- Manpower (used for Reporting purposed) is reduced by 40%
- Response Time to Customer Queries reduces from 1 day to 30 mins
- Customer Report Preparation Time reduces from 2 weeks to 1 day
This Manufacturer produces Silicon Rubber Compounds used in Semiconductor IC Packaging. Each Production Lot requires a Certificate of Conformance (CoC) before they can be shipped out to the customers.
Before the Implementation of the Real-time QC and SPC Software, after the Finished Goods are produced, sampling is done on each lot of Finished Goods based on AQL (Acceptance Quality Limits). In many instances, the CoC cannot be completed on time due to the time and resource consuming manual CoC preparation procedure.
The Real-time QC and SPC Software implemented in this factory is designed with the following workflow:
- Every 30 mins, the operator must enter the Volume and the Weigh of the Silicon Rubber Tablet Samples into the Software during production and the software will automatically determine whether the Density of the Silicon Rubber Tablet Sample is Out Of Control or Out of Specifications.
- If the Out Of Control or Out of Specifications condition is detected, the Operator cannot continue operation until the problem is resolved and corrective actions are taken.
- At the end of the successful production of each lot, the software will automatically print the CoC. By doing so, each lot that is produced will definitely have a CoC.
Other Benefits Enjoyed by this manufacturer from the implementation of the Real-time QC and SPC Software are:
- Minimal Scrap and Customer Claims
- The Operator works according the workflow in the software. This significant reduces Operator Training and Product Quality Discrepancy