Production Performance Results Internet Sample

Production Performance Results Internet Sample

• 1.
  Jan.06.2004 Monthly BusinessReview Contents 1. Key Initiatives 2. Issues Appendix : December, 2003 President Customer Director Prepared by A.Arenas
• 2.
  Dec. Productivity (FinalLines) Match Job required Profile to operator . Incentive Programs Out Source Non Critical Operations Ctrl Idle 12.3% 38.2% Purchasing Effi. Lose 3.9% 12.6% Plastics Issue Solution Purchasing : Continiuosly Late with Material Creating Schedule Changes and Idle Time Plastics : Delivery and Quality Problems . Secure Proper Logistics and Accuracy in ETA’a prediction . Safety Stock of Critical Parts . Plastics has booked 2004 C/A Plan to Counter this Situation – Tracking- 71% Issue Solution Absenteeism: High (4.4%) Turn Over (22) 22% Production (OJT) Absenteeism 3 /4 Production : Skill Up of Operators is required . Screening and Profiling For NDP Line Personal. PQC Technician 2 Days Frozen Schedule 100% Ctrl Idle 12.3% 0.9 RW 1.6% Indirect 3.4% 81.8% Total Input Hrs Net Direct Effi. Lose 15.3% 66.6% RMH Total Losses
• 3.
  3. Issues Risk& Opportunity Major Activities Productivity Improvement (TE Capability to Detect more defects ) . Re-arrange Operators /supervisor to Improve productivity TDR Team working to Improve NDP Line Productivity by 233% Low Productivity in Line 6 due to design changes (ECO’s) , Frequent Model Changes , Material Quality , Material Shortages , and Operators Absenteeism and Skills . Any Rework required to be done before Delivering to Final Line Material Delivery Tight to meet Schedule NDP Line Packing Area Problems NDP Line Conveyor Logic Errors Activities Good & Bad Task Team (TDR) to address Process opportunities . Training for Cross Functional Operators and stronger Relief operators . Develop Product Experts for NDP Line Action Plan Issues Solutions Allocation of a group to address Rework caused by incoming material . TPSG to Provide On The Job Training to new Operators . Material Expeditor Line Fallout (Skills, Criteria , Equip. Turn Over Clean Room (To Prevent Contamination) Automatic Hi-Pot Verification Use Chassis after Functional test only Define CTQ’s and CTP’s Establish disciplinary Guide Lines 4 / 4
• 4.
  MBR Review Contents KPI Top 3 Contributors for RMH / Quality / PSA Attachments 1 of 15 President Customer Director Prepared by A.Arenas
• 5.
  24.1% 15.8% 100%FINAL RMH Analysis for Dec.’03 Action Plan Status Total DT = 12.3% 7.1% Purchasing Reinforce the Inbound Logistics with experience Buyer / Planner . Review and Update Procedures Measure Carrier Performance On Going 53.1% TE Purchasing Plastics Other 100% Sub-Assy Final RMH 3 of 15 IQC LCD Line Fill Diode Short in Chassis Box Other Delivery + Quality Purity / IC5100 Damage EDIT (L6) Equipment Plastics Plastic Plant Has Provided their Detailed C/A plan to Improve this category . - Monitoring- On Going Test Equipment Test Equipment has been asked to Provide a detailed Plan on How to Improve this category . On Going
• 6.
  36.1% 28.8% 57.5%67.4% Chassis RMH Analysis for Dec’03 Action Plan Status Total DT = 12.9 % 23.5% On Going Purchasing Reinforce the Inbound Logistics with experience Buyer / Planner . Review and Update Procedures Measure Carrier Performance Transistor Purchasing IC Diode 13.5% Other TE Empty out Lines for Inventory Checksum Chassis RMH 4 of 15 Other Mech. Maint. Plastics 32.6% Move to Component Plt. 42.5% Functional + VT equipment Test Equipment Test Equipment has been asked to Provide a detailed Plan on How to Improve this category . On Going Other Time required to prepare for Year –End Inventory (empty out Lines) . Time Required for ACI / Chassis Move to Component Plant . Closed
• 7.
  36.1% 13.8% 39.8%Final Quality Analysis for Dec’03 Action Plan Status Total Defects = 1394 Other Electrical Parts Main Contributor this Month were Defective Module for NDP Line . TDR team to Improve Quality has been active and is schedule to finish in Dec. New TDR to Improve Productivity started in Dec’03 7.4% 6.8 Plastics Chassis Part Elect. Module 9.2% 63.2% Distorted Video Defective Digital Bd. On Going Final Quality 5 of 15 LCD Related Defects : Programming / No Turn On / No Video / Solder Shorts 6.2% 5.8% No Audio 49.8% Other Scratches 13.8% Nicks Bubbling Other B&W Tracking (Video Output) No Audio (JkPAck) 46.0% Other Module Plastics Plastic Plant Has Provided their Detailed C/A plan to Improve this category . - Monitoring- On Going Detectability in Module/Chassis Area needs to Improve . A TDR Team will be Charged with this activity . On Going
• 8.
  85.2% 14.8% 68.8%16.7% 58.7% Chassis Quality Analysis for Dec’03 Action Plan Axial Status Total Defects = 511 Soldering Radials 20.0% Others Constructing a detailed Data Base with Root Cause On Going Analysis for each Opportunity. Follow – up to conclusion each of the opportunities On Going Increased APC testing by Prioritizing High Runners On Going Constructing a detailed Data Base with Root Cause On Going Analysis for each Opportunity . Follow – up to conclusion each of the opportunities On Going Increased APC testing by Prioritizing High Runners On Going 8.0% Axial Soldering Radial W/Line Solder Short Missing Wrong Missing Wrong High Runners Prioritization =============> Chassis Quality 6 of 15 No Solder 14.5% Other Other Soldering Peaked out of Goal due to Flux from Doo Sung contains High Level of Solids = 12% . Our Normal Flux from Alpha Metals contains 8% . Alpha metal Flux in House and now being used . Closed
• 9.
  90.6% Rework Analysisfor Dec’03 Action Plan Test Equipment Problem in Test equipment has been corrected check list implemented to control Status Total Rework cost = $ 5,051.79 100% Design Test Equip. 47.7% Closed All problems were ID and Fixed . PAT Full Approval Check List is Required Closed Open Mgmt. Decision 26% Management decision In order to Prevent greater losses it was decided to Rework Domex Yoke Cable in LGERS . Approx.16K were reworked Closed Rework 7 of 15 Due to Bad AGC Set-up In Chassis Area . 9.4% CSA Label Not Implemented Design Change Yoke Cable on Domex 20” CRT Video Mute Problem Add Capacitor for RGB PIP 23% Distorted Menu . Change Internal register Production Other
• 10.
  66.6% Scrap Analysis for Dec’03 Action Plan Total Scrap = $ 26,601.00 41.0% 88.6% Scrap 3141-Chassis by Mech. Devices 687-PCB Damage By Machine Details Fine Tuning of Conveyor system and Mechanical Devices During ACI and Chassis Move to Component Plant Actions Expedite Analysis Quickly ID Scrap Owner Immediately Process Scrap Report Chassis Final ACI Other Material 8 of 15 Module 14.0% 19.4% 3141-Chassis By Machine 60.4% Other 6401-Speaker (Obsolete) 11.4% Other (Obsolete) 687-Module Machine Damage
• 11.
  Over Time Analysis for Dec’03 Action Plan Total Over Time = $ 144,273.20 Over Time Scheduling Volume required Volume required 89 % of all OT expense 9 of 15
• 12.
  Absenteeism Analysisfor Dec’03 Action Plan Total Absenteeism = 4.4% Absenteeism Other Sickness Dead / Sick Relative No Reason Given Resign Wake Up Late HR has been requested to Activate a Program that will revert this situation . Some Ideas are : Superintendent and Supervisor Training in Human Resources Management Incentive Programs revised to make the return of personal more attractive. Reward program for perfect attendance (accumulative / and penalties Included) to pay at end of year . Review days Payments are made and revised if so required ,. 10 of 15
• 13.
  2003 LGERS PERFORMANCEINDEXES 11 of 15
• 14.
  2003 LGERS PERFORMANCEINDEXES cont... 12 of 15
• 15.
  New 2 nd Half Manufacturing 6 Sigma Teams 94% Manufacturing Area has Reached their KPI Goal in # of 6 Sigma Themes for 2003 We missed reaching our Green Belt Goal by 1 for this year . No Black belt Certification will be Conducted this year. Max Opportunity for BB =2 of which 1 got certified . Dropped (Resigned) 15 of 15 Budget Status 6 SIGMA THEMES Define Measure Analize Improve Control Bud. Adv. Optimize Balance Delay Time (LOB) in Chassis July to Oct 100% 96% Improve In Process Quality in Final Lines July to Oct 100% 80% Optimize Balance Delay Time (LOB) in Final Lines July to Oct 100% 100% Optimize WIP in Chassis area July to Oct 0% 0% Nov Dec July Aug Sep Oct Leader Stage of Project Team Members Timing Remarks Define Measure Analize Improve Control Bud. Adv. Optimize model change ACI May to Oct 100% 100% May Jun July Aug Project Leader Sep Oct Theme Green Belt Black Belt Super " A" YR'2003 Actual YR'2003 Goal 6 10 3 1 9 9 1 1 6 Sigma Status Budget Status 400% 376%