Zero Defect

Kaizen Promotion Office

Global Business Excellence
Team Leader : SY
Section : KPO
Date : Mar 8,2011

Design. Build. Ship. Service.

Zero Defect – Eliminate Cost Of Quality

Zero Defect Theme : Eliminate Cost Of Quality

Opening
Quote
a) The Quest for Zero Defects – Mike Richman
b) Quality is Free – by Philip B.Crosby
Benefits
Systematic Approach – Pre-requisit
Prevention – Examples
(1 pc flow, 5S+1,Fish market, Andon triggering, Poke yoke, Visual system & TPM)
Solving – Examples
( 5why/7 ways, Autonomation, Hourly Defect Tracking, Six Sigma & Defect Mapping)
Process Shikumi
( 8 Steps Structure Guide Towards Zero Defects)
Physical Shikumi (live example)
( Show physical line with Andon(POD), Fish market(POD) & POO location)
Yield trending with success story
Success story BP
a) From different sites
Closing

Design. Build. Ship. Service. 2

“The quality manager must be clear, right from the start, that zero defects is not a motivation
program. Its purpose is to communicate to all employees the literal meaning of the words ‘zero
defects’ and the thought that everyone should do things right the first time.”
--Quality Is Free by Philip B. Crosby (McGraw-Hill Books, 1979)

Design. Build. Ship. Service. 3

Zero Defect – Eliminate Cost Of Quality

Framework
Future state:
Benefit/advantages:-Eliminate all form of Waste
• Without a companywide commitment to zero defects, the more common goals of
‘improve the business’ or ‘reduce defects’ limit progress
• The zero defect methodology provides an elevated level of excellence.
• Cost reduction due to the fact that time is now being spent on only producing
goods or services that are produced according to the requirements of customers.
• Possible to measure the cost of quality by building and delivering a finished
goods that conforms to customer requirements at all times will result in increased
customer satisfaction, improved customer retention and increased profitability.
• Right conditions of process, system or method of working have to be
established to allow Zero Defect achievement to take place. Resulted cost
reduction caused by a decrease in waste.
• This waste could be:-
wasted materials, human resource, space and wasted time due to unnecessary
rework

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Zero Defect – Eliminate Cost Of Quality

Defect Vs Cost

Defect

Cost $

Design. Build. Ship. Service. 5

Zero Defect – Eliminate Cost Of Quality (Proof)

Mechanical PCBA Assembly System Assembly

Yield improvement by ?%. Yield improvement by ?%. Yield improvement by ?%.
Productivity improvement by 85%. Productivity improvement by 50% Productivity improvement by 40%.
WIP reduction by 75%. WIP reduction by 70% WIP reduction by 80%.
Eliminate customer complaints on quality by 100%. Eliminate customer complaints on quality by 100% Eliminate customer complaints on quality by 100%.
Scrap reduction by 75%. Scrap reduction by 30% Scrap reduction by 80%.
Manufacturing lead time reduction by 55%. Manufacturing lead time reduction by 45% Manufacturing lead time reduction by 67%.
Total machine downtime reduction by 65%. Total machine downtime reduction by 60% Total machine downtime reduction by 85%.

Design. Build. Ship. Service. 6

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Design. Build. Ship. Service. 7

Zero Defect – Eliminate Cost Of Quality (Pre-Requisite)
Solving

Fish Market Andon Light Autonomation

Run fish market, 4W/1H,

Andon light to trigger action for System auto-stop line if detect
POO,POD and 5 whys to drive
defect found. failure
ETE Yield Improvement

Six Sigma Defect Mapping Hourly Defect Tracking

Normal plot in DOE is used to Actual Defect position To track defect hourly toward zero
determine which factors which have defect
interaction or main effects are
significant

Design. Build. Ship. Service. 8

Zero Defect – Eliminate Cost Of Quality (Pre-Requisite)
Prevention

Visual Management TPM Defect Mapping for Reflow oven

1 Piece Flow
Process sign Current Should Be Measurement
Drawing Parameter Condition Condition How to Control Method/Tools Frequency Who

Separate the parts by process Temper latu ± 5℃ Check this every check this every once each Raw
P eviation Zone Deviation ± 5℃ Max four hours four hour four hour IP QC Material
$
check this by check this by Online
Trans port speed 75 CM / Min 75 CM / Min online Technician online Technician Each s hift Technician $$
$
$$
w
$$
fubration ovent Every half Online

$
flo volume control No Yes Visual Ins pection Visual Inspection on hour Technician
ss Partition line Finished
ce of process Oven lane current model
Batch
P ro distortion PBA check on S tandard (New) once for Online Goods
confirm Yes Yes the came PCB every s hift Technician

Move products in accordance with Defect management plan, to know Move towards 1 piece flow,
the progress of process flow current and should be condition eliminate batch production

Poka Yoke 5S + 1

Detect the position

on the first attempt
Setting jig
Silicon
coating

Parts set Tighten a

screw
No need of positioning by Color code template used to visually guide
using jig. correct wires and speed up wiring process

Design. Build. Ship. Service. 9

Process Shikumi

POO & POD

7QC - Defect pareto chart, checksheet, histogram, hourly tracking control chart.
Fish Market

Root Cause Finding (5WHY)

7QC – Fish Bone

7 WAYS
Defect Management Plan
Poka Yoke

Hourly tracking control chart – continue…

Jidoka. Can solution be automated?

Standard Worksheet

This simple methodology, together with its tools, when institutionalized as a culture and day-to-day
practice at the shopfloor, will produce distinctive and visible results of ZERO DEFECTS.

Design. Build. Ship. Service. 10

Process Shikumi

The 8-Step Structured Guide Towards Zero Defects

Step 1 Step 2 Step 3 Step 4 Step 5

Data Collection and Root Cause Analysis Counter Measure Tried Counter Measure Data Collection On
Analysis of Data Effectiveness Of
Counter Measure

Hourly Defect 5 Why Analysis Counter Measure Try On The New Hourly Defect
Tracking Top defects Defined Counter Measure Tracking On
Effectiveness

Step 6 Step 7 Step 8

Changes No Impact To No Cost Impact Sustainable
Output And No New
Defect Created

Measure Output Confirmation Sustainable

And If Any Defect Of No Major Cost Through Standard
Detected From New Incur On New Work
Counter Measure Counter Measure

Design. Build. Ship. Service. 11

 Create sense of urgency & treat defect
Physical Shikumi like fire burning on house

POO 1 POO 2 POO 3 POD

PROCESS 1 PROCESS 2 PROCESS 3 PROCESS 4

Hourly Tracker Hourly Tracker

Fish Market
1. When defect is detected at POD (by Operator or Machine)
Apply
2. Place defect on the Fish Market & trigger the Andon light
3G 3. Supervisor/Technician/Engineer/CFT IMMEDIATELY go the POD
4. Stop the line, bring defect units & do defect analysis at POO
5. Monitor defect trend using Hourly Defect Tracker

Target
1 hour > 0 defect
4 hours > 0 defect
1 shift > 0 defect
1 day > 0 defect
Auto Lock the machine when repeated defect is detected.
Only Production Manager / Quality can unlock the machine after defect is resolved.
Design. Build. Ship. Service.
Lean In Quality – HP Top Level ETE Yield Improvement

Top Level ETE Yield Improvement Trend

88.5%
90.00%
 =1.0 mm
88.00% 88.19% 88.41% 88.50%
86.00% 86.30%
3C 85.06% 85.60%
84.81%
84.00% 84.09%
82.75% 83.08%
82.00% 81.68%
80.28% 80.75%
80.00%
80.3%
78.00%
Sharp edge
76.00%  = 0.6mm 2C

WK01 WK02 WK03 WK04 WK05 WK06 WK07 WK08 WK09 WK10 WK11 WK12 WK13
TL ETE yield improved from Feb’s 80.3% to current
88.5%
Design. Build. Ship. Service.
Zhuhai FMC(HP) : ETE Quality Improvement

Area of Application : PCBA and Top Level

Challenges : Low ETE Yield for PCBA and Top Level, It creates High scarp

and low productivity

Solution : System Kaizen, Engineering kaizen, Layout kaizen and POKE
YOKE solution to improve ETE Yield for PCBA and Top Level
Achievements : PCBA ETE yield improved from 73.4% to 97.1%,Top Level ETE
yield improved from 80.3% to 88.5%
Before Kaizen After Kaizen
HP PCBA ETE Trend - Main Board

100%
97.10%
95%
93.50%
90% 90.70% 90.80%

85% 85.00%
82.30% 83.20%
81.30% 81.80%
80%
77.60% 78.40% 77.80% 78.37%
76.38% 76.49%
75%
73.37% 72.46%
70%

65%

60%
W0949 W0950 W0951 W0952 W1001 W1002 W1003 W1004 W1005 W1007 W1008 W1009 W1010 W1011 W1012 W1013 W1110

Design. Build. Ship. Service.

Zero Defect – Eliminate Cost Of Quality

Summary - Ending

ZERO DEFECTS ADVOCATES endorse continuous improvement. This is the

never-ending effort to totally eliminate all forms of waste (the Japanese call
it“muda”), including reworks, yield losses, unproductive time, over-design,
inventory, idle facilities, safety accidents, and the less tangible factors of
unrealized individual and societal potential. The methods used in this process
are widely misunderstood and in fact may lie at the root of the issue. The
Japanese word for continuous improvement is “kaizen.” Kaizen represents
inexpensive and almost imperceptible continuous improvement.

Maximum Quality Level, Equals Zero Defects

Design. Build. Ship. Service. 15

Zero Defect – Eliminate Cost Of Quality

Appendix

Design. Build. Ship. Service. 16

 Best Practice Source: Internal
Lean in Operations – Quality Release 12-43 Site Name: Dallas, TX
Title: Color Code Templates for easy installation of wires Month, Year: July, 2010
[email protected]

Operations/
Problem Action Taken Results Method for Sustaining
Station

% Improved
NCR control panel sub Color code templates Savings
Inventory /

Before
assemblies presented designed and implemented Metrics

After
Hard Soft
STA 3, 4, 5 and 6 miswiring issues, delaying on the line to facilitate the AR/AP Visual Management
(UOM) (USD/ (USD/
(USD/
production increasing no correct identification of the month) month)
month)
value added for trouble right location for
Customer shooting and repair. connection of the wires. # of
5 0 100% 340 0 0 Implementation Start Date
Templates used during the defects 1-Jul-10
NCR assembly process. 100% Implementation Plan
2-Jul-10
Tools Used Goals
Potential Savings/Month
X Defect x1/10 Lead-Time x1/2
after 100% Implementation
X Lean
Inventory /
Inventory x1/2 Scrap x1/10 Hard Soft
AR/AP
Six Sigma X Productivity x2 Space x1/2
US$0.34K US$XXK US$XXK

Before Kaizen After Kaizen

Color code template used
to visually guide correct
wires and speed up wiring
process

Swapped Site Yokoten

Implementation Status:
wires. Guide: 81% ~ 100%

Design. Build. Ship. Service. 17

Zero Defect – Eliminate Cost Of Quality (Pre-Requisite)
Fish Market

collect data to do 5WHYs

for yield improvement

Run Fish market, 4W/1H,

Control by FlexFlow to shutdown POO, POD and 5 whys to
and alarm when over 4H
drive ETE yield improvement

Run fish market, 4W/1H, POO,POD and 5 whys to

drive ETE Yield Improvement

BP:8-51

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Zero Defect – Eliminate Cost Of Quality (Pre-Requisite)
Fish Market

for yield improvement

Run fish market, 4W/1H, POO,POD and 5 whys to drive

ETE Yield Improvement

BP:8-51

Design. Build. Ship. Service. 19

Zero Defect – Eliminate Cost Of Quality (Pre-Requisite)
Andon Light

Andon Light

- Fail Analysis
- POO x POD Matrix
- Action Plan

BP: 11-54

Design. Build. Ship. Service. 20

Zero Defect – Eliminate Cost Of Quality (Pre-Requisite)

Visual System Process sign

Kanban Post Separate the parts by process

f low
ss
o ce Partition line
Pr of process

Move products in accordance with the progress of process

flow. Can tell the progress of process depending on the
stopping place of products.
BP :13-21

The key can stop

production line

BP: 12-44

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Zero Defect – Eliminate Cost Of Quality (Pre-Requisite)

Poka Yoke

Detect the position

No need of positioning by on the first attempt
using jig. Setting Jig

Silicon coating

Parts set Plate set Tighten a screw

BP: 12-27

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Zero Defect – Eliminate Cost Of Quality (Pre-Requisite)

Defect Mapping

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Zero Defect – Eliminate Cost Of Quality (Pre-Requisite)

Hourly Defect Tracking

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Zero Defect – Eliminate Cost Of Quality (Pre-Requisite)

Autonomation

BP 13-40

Design. Build. Ship. Service. 25

Zero Defect – Eliminate Cost Of Quality (Pre-Requisite)

TPM

Defect Mapping for Reflow oven

Current Should Be Measurement

Drawing Parameter Condition Condition How to Control Method/Tools Frequency Who

Temper latu ± 5℃ Check this every check this every once each
P eviation Zone Deviation ± 5℃ Max four hours four hour four hour IP QC

check this by check this by Online

Trans port s peed 75 CM / Min 75 CM / Min online Technician online Technician Each s hift Technician

fubration ovent Every half Online

volume control No Yes Vis ual Ins pection Vis ual Ins pection on hour Technician

Oven lane current model

dis tortion P BA check on S tandard (New) once for Online
confirm Yes Yes the came P CB every s hift Technician

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Zero Defect – Eliminate Cost Of Quality

1 Piece Flow Move Towards 1 Piece Flow, Eliminate Batch Production

$
Raw
Material
$
$
$
$$
$$
$
Finished
Goods

 Right TAKT time calculation is

critical to one piece flow process
 Use ETE TAKT Time Table to
calculate TAKT time
 One Piece Flow => Std WIP

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Zero Defect – Eliminate Cost Of Quality (Pre-Requisite)

Six Sigma

• Normal plot in DOE is used to determine which factors which have interaction or main effects are significant.
 Main Effect plot in DOE is also used to determine individual contributing factors.

Design. Build. Ship. Service. 28