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Ems Productivity Improvement Apr 07

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J
jansencheng

This productivity improvement plan outlines 10 initiatives to reduce manpower costs in Q3 of 2007. These include changing production lines to a stand-up operation, automating component preforming, outsourcing reduction, and improving standard times. An estimated 40 operators will be reduced through line changes, 28 operators by implementing step-up stencils, and 22 operators by automating FFC cable soldering. The attached file with details has been deliberately deleted to protect intellectual privacy.

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Productivity Improvement Plan Year 2007, Q3 Prepared: Jansen Cheng (Manufacturing Engineering Manager) Review: P.C. Yeung ( Sr. Operation Manager )
Content¨Cmanpower reduction ¡ñ 1. Production line change to Stand up operation ¡ñ 2. Step up stencil ¡ñ 3. Recycle solder bar ¡ñ 4. FFC cable hand soldering ¡ñ 5. Component Preform automation ¡ñ 6. Outsource reduction ¡ñ 7. Electricity expense
Content ¡ñ 8. Standard time improvement ¡ñ 9. Inspection headcount ¡ñ 10. Floor space allocated ¡ñ Attached files : Details of this presentation please ref to the attached file: manpower reduction 20070413.xls
Production line change to Stand up Operators are stand up to work, efficiency is increased by 5.7 % and up to 20% in some case. Floor space is increased by reclamation. Preform lines
Production line change to Stand up Already implemented in Manual insertion, WS and packaging lines, and most of the Preform lines. Manual insertion WS to packaging
Production line change to Stand up ¡ñ Nine of fourteen lines will change to Stand up operation before Jun.2007. ¡ñ Totally reduce 40 operators ¡ñ Responsible : M.E. Dept.
Step up stencil Use "Step up stencil" to add extra glue to the IC location. The ¡°hand- add-glue¡± operator is saved. ͨ¹ý¿ªÉèÏò ÉϿ׶´£¬ ¿ÉÒÔÔö¼ÓÑ¡ ¶¨Ôª¼þ µÄ red glue ÓÃÁ¿¡£ Before change New Step up stencil
Step up stencil ¡ñ Affected 14 lines by reduce one operator per SMT line. ¡ñ Totally reduce 28 operators. Complete before May.31. ¡ñ Responsible : M.E. Dept.
Recycle solder bar ¡ñ Using Recycle machine to regenerate solder bar ¡ñ Saving is 7 % of monthly solder consumption ¡ñ Countermeasure to rising price of SAC305 solder
Recycle solder bar - RoHS Compliance Test ¡ñ The sample will also be subjected to RoHS compliance testing using XRF analyzer in our QRS Lab. ¡ñ Responsible : QA
FFC cable hand soldering ¡ñ Replace hand soldering process by Heat seal machine to solder FFC. ¡ñ Total reduce 22 operators. ¡ñ Complete date: Jul.2007 ¡ñ Responsible: M.E. dept. Heat seal machine
Component Preform automation ¡ñ Hand cutting lead change to machine cutting. ¡ñ Two operators is saved. Affected 6 lines. ¡ñ Responsible: PIE dept.
Outsource reduction ¡ñ Add new Auto-insertion line in Production and reduce outsource equivalent line equals to 2 lines. ¡ñ Complete by: Apr.07 ¡ñ Responsible: M.E. dept.
Electricity expense ¡ñ Use city electricity to replace power generator in-house. The electricity cost is reduced. ¡ñ Responsible: PTE dept
Standard time improvement ¡ñ Work with CEE to improve std time. ¡ñ Continuous improvement by regular review of std time. ¡ñ Responsile: CEE, M.E.dept. and Production
Attached file ¡ñ manpower reduction 20070413 (rev1).xls, this file is delibrately deleted to protect intellectual privacy. ¡ñ The content of this presentation file is not allowed to reproduce without permission of the author.

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Ems Productivity Improvement Apr 07

  • 1. Productivity Improvement Plan Year 2007, Q3 Prepared: Jansen Cheng (Manufacturing Engineering Manager) Review: P.C. Yeung ( Sr. Operation Manager )
  • 2. Content¨Cmanpower reduction ¡ñ 1. Production line change to Stand up operation ¡ñ 2. Step up stencil ¡ñ 3. Recycle solder bar ¡ñ 4. FFC cable hand soldering ¡ñ 5. Component Preform automation ¡ñ 6. Outsource reduction ¡ñ 7. Electricity expense
  • 3. Content ¡ñ 8. Standard time improvement ¡ñ 9. Inspection headcount ¡ñ 10. Floor space allocated ¡ñ Attached files : Details of this presentation please ref to the attached file: manpower reduction 20070413.xls
  • 4. Production line change to Stand up Operators are stand up to work, efficiency is increased by 5.7 % and up to 20% in some case. Floor space is increased by reclamation. Preform lines
  • 5. Production line change to Stand up Already implemented in Manual insertion, WS and packaging lines, and most of the Preform lines. Manual insertion WS to packaging
  • 6. Production line change to Stand up ¡ñ Nine of fourteen lines will change to Stand up operation before Jun.2007. ¡ñ Totally reduce 40 operators ¡ñ Responsible : M.E. Dept.
  • 7. Step up stencil Use "Step up stencil" to add extra glue to the IC location. The ¡°hand- add-glue¡± operator is saved. ͨ¹ý¿ªÉèÏò ÉϿ׶´£¬ ¿ÉÒÔÔö¼ÓÑ¡ ¶¨Ôª¼þ µÄ red glue ÓÃÁ¿¡£ Before change New Step up stencil
  • 8. Step up stencil ¡ñ Affected 14 lines by reduce one operator per SMT line. ¡ñ Totally reduce 28 operators. Complete before May.31. ¡ñ Responsible : M.E. Dept.
  • 9. Recycle solder bar ¡ñ Using Recycle machine to regenerate solder bar ¡ñ Saving is 7 % of monthly solder consumption ¡ñ Countermeasure to rising price of SAC305 solder
  • 10. Recycle solder bar - RoHS Compliance Test ¡ñ The sample will also be subjected to RoHS compliance testing using XRF analyzer in our QRS Lab. ¡ñ Responsible : QA
  • 11. FFC cable hand soldering ¡ñ Replace hand soldering process by Heat seal machine to solder FFC. ¡ñ Total reduce 22 operators. ¡ñ Complete date: Jul.2007 ¡ñ Responsible: M.E. dept. Heat seal machine
  • 12. Component Preform automation ¡ñ Hand cutting lead change to machine cutting. ¡ñ Two operators is saved. Affected 6 lines. ¡ñ Responsible: PIE dept.
  • 13. Outsource reduction ¡ñ Add new Auto-insertion line in Production and reduce outsource equivalent line equals to 2 lines. ¡ñ Complete by: Apr.07 ¡ñ Responsible: M.E. dept.
  • 14. Electricity expense ¡ñ Use city electricity to replace power generator in-house. The electricity cost is reduced. ¡ñ Responsible: PTE dept
  • 15. Standard time improvement ¡ñ Work with CEE to improve std time. ¡ñ Continuous improvement by regular review of std time. ¡ñ Responsile: CEE, M.E.dept. and Production
  • 16. Attached file ¡ñ manpower reduction 20070413 (rev1).xls, this file is delibrately deleted to protect intellectual privacy. ¡ñ The content of this presentation file is not allowed to reproduce without permission of the author.