Reducing exposed copper on annular rings in a PCB factory through implementation of a Six Sigma project

Abstract

As a well-structured methodology, Six Sigma enhances product quality by analysing data using statistical approaches to identify root causes of problems and implement effective control plans. This study presents a Six Sigma project at a printing circuit board (PCB) company illustrating how a Six Sigma project and statistical methods have been applied. The defect of exposed copper on annular rings during the developing process was examined. By using qualitative and quantitative tools in the define, measure, analyse, improve and control (DMAIC) methodology, the critical outputs, key point inputs and root causes were identified, analysed and verified. Additionally, a number of temporary and long-term control plans were developed to sustain and enhance the performance of the developing process. Finally, the benefits, experience, and extensions of the Six Sigma project were discussed.

Six sigma, absorptive capacity and organisational learning orientation

“…If we translate this concept to an internal perspective, as Tu et al (2006) do with the definition of absorptive capacity, Six Sigma typically brings about a cultural change in the organization. Lee et al (2009) identify this change as the most important aspect of the methodology. Thus, the right cultural change, with a clear communication plan and channels that motivate the employees to overcome resistance to change (Antony and Bañuelas, 2001) will produce work units that share all of the characteristics indicated by Lane and Lubatkin (1998) and Lane et al (2001), developing the presence of relative absorptive capacity.…”

Reducing the Scrap Rate in Manufacturing SMEs Through Lean Six Sigma Methodology: An Action Research

“…LSS has been strongly suggested by a longitudinal study to promote a sustainable process improvement in manufacturing organisations including SMEs [5,22,32,[38][39]. At an operational level within the manufacturing sector, the LSS model aims to clarify the process of identifying opportunities for non-value added activities, as well as reduce variability and improve the process cycle time and quality of the manufacturing process [25,[40][41][42][43][44].…”

Exploring the Fundamentals of Root Cause Analysis: Are We Asking the Right Questions in Defining the Problem?

“…According to Kwak and Anbar, 28 Six Sigma differs from other improvement programs in its 'top-down' approach and rigorous methodology that demands detailed analysis, fact-based decisions and effective control plan that ensures ongoing control of a process. Although Six Sigma was typically first implemented to improve manufacturing processes, Lee et al 29 explained that the method can also be in other business processes, such as product design, customer service and supply chain management. For example, Antony and Banuelas 30 stated that several companies, including Motorola, General Electric, Honeywell, Bombardier and Sony, have reported significant benefits from Six Sigma initiatives.…”