Page 85 - How To Implement Lean Manufacturing

66 Cha pte r F o u r

A Continuous Improvement Methodology
(How to improve a process of n steps)
Step one Final
Collect data Raw mat’l Oper 1 Oper 2 Oper n product
for the process

Continuous process problems
Pareto analysis Jan-Mar
Top five Qty Total count = 122
problems 130
Step two 117 (86%) 100
Defect A 58 Create Pareto 104 (75%) (95%) 90
80
Defect B 33 analysis to 91 70
78
Defect C 14 prioritize Count 65 (48%) 60 Percent
50
Defect D 11 problems 52 33 40
39
Defect E 6 26 14 30
20
13 11 6 10
0 0
Defect-A Defect-B Defect-C Defect-D Defect-E
Step three
Monitor top defect
using a control chart
Material Manpower Measurement RIC 2S40 M3 1ER TURNO, PARAMETRO
Gauge R & R Calibration
60000
Defect A 50000 UCL
Maintenance Lubrication 40000
Method Operation PPM 30000
20000 AVG =
Machine 0.019103
Step five Step four 10000
Standardize the If cause is unknown 0
fix using an Xbar perform a cause and 3/2/92 4/2/92 5/2/92
R chart to control key effect analysis to
process parameters identify root cause
and modify PNCP of the defect and fix it Step six
Confirm that FTY has increased and
the solution is standardized and effective.
Diode holder
If so, return to Step One and continue the process
Width-INS UCL = 1.4763
AVERAGES 1.4765 AVG = 1.4740 94 First time yield
1.4755
1.4745
1.4735
92
1.4725
LCL = 1.4718
1.4715
90
RANGES 0.0075 UCL = 0.0071 FTY % 88
0.0060
86
0.0045
84
RBAR = 0.0031
0.0030
0.0015
0.0000 LCL = 0.0000 1 2 3 4 5 6 7 8
1 3 5 7 9 11 13 15 17 19 Weeks
2 4 6 8 10 12 14 16 18 20
FIGURE 4-1 Continuous improvement fl ow chart.