Continuous Process Improvement is methodology to solve the defect problem by increasing the effectiveness and efficiency of the business performances. DMAIC (Define-Measure-Analysis-Improve-Control) is a data improvement cycle designed for business process to find flaw or inefficiencies particularly resulting in defect or reject. This study was conducted at Company A and used DMAIC method to reduce the open defect for the circuit on the Flexible Printed Circuit Board (FPCB) from 0.6% to 0.3%. Part 13236 which has the highest open defect problem was chosen as the project improvement main focus. Imaging area was the main focus in this project because of its process forming the circuit. DMAIC methodology are initiated by problem identification through the past record of the open defect. The result observed for period of four months. After improvement, Part 13236 that have the highest defect decrease from 0.68% to 0.28% while the overall open defect decreases from 0.6% to 0.3%. The decline on product defect rate helps the company to improve the effectiveness and efficiency of business performances. It also results in cost saving which improves company’s profit margin in the long term.
This study addresses the improvement of first pass yield on the production floor of ABC Semiconductor. ABC is a company running a multiple volume complex product in aligning with memory business in the operation. First pass yield refers to the proportion of fully built product that pass testing without the need for additional rework. The first pass yield (FPY) project showed steady progression for its first five years. But over the following one year, the primary yield metric which is first pass yield has stayed stagnant. The goal of the paper presented here is to analyze the reasons for the current performance and propose novel ways of improving the metric again using quality management tools. The most common is using 7QC tools method by categorizing failure pareto that will lead to targeted corrective action to reduce the recurrence of pre-identified failure modes. A DMAIC methodology is establish on how to define an efficient corrective action, along with a top three major defect on data acquired from ABC organization. From the exercise, the yield loss was able to be reduced from 17.4% to 3.52%.
Phosphating is most common method for surface treatment and finishing of ferrous and nonferrous metal. It has excellent corrosion resistance, wear resistance, adhesion and lubricating properties besides its economic values and speed of application. Steel is one of the cheapest materials used in various industries and it requires corrosion resistance therapy. This study aims to provide possible solution to the rusty issue on carbon steel product by improving coating stability using Defining–Measuring–Analysing–Improving–Controlling (DMAIC) method. The result proposed that zinc phosphate coating material has to replace current iron phosphate coating due to the former is more corrosion time resistant than that of the latter.
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