process improvement

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FTTP Road Map Part Number : QC2-5967-000 Part Name : EJECT SUB TRAY Model : Production Area : Fischer-Pratumtanee Problem Description : No Cutting Flash on CAV#1 Date : 19-Feb-09

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Team P. Surachai - PD K. Somkid - Plan K. Narong - WH K. Teepakorn - PE K. Tussanee - QC K. Sumreung - Mold W. Natawut-QC

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Problem Description CHT found defect on the 20-Feb-09 in the assembly site at 350 pcs with the CAV#1 for flash cutting incomplete over the specification control and inform to supplier to clarify with FTTP Stock before shipment on 20-Feb-09

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Interim Containment Action (ICA) - Implement QA tighten for sampling with 100% Inspect before shipment -------( Done ) - Implement PD separate with CAV#1 and 100% Inspection before shipment ----( Done ) Scrup with cutting holder inspection Inspection + Tag Inform for finishing Area

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Work Flow Diagram(Current) Injection Finish& Insp Pack Sampling Outgoing Store Production Process Division Failure Majority Production Production IPQC 0.25% OQC 0.25% Warehouse Use 4 Cavity /Shot (20 sec) No Separate Cav # to control No More time to finishing No Support for Breaking Time. Operator’s unknown with the suitable defect. Non Detect Loose to sampling Unknown the criteria. Line Balance Unclarify Manage Unclarify Criteria Activity Mold Improve Line Manage Clarify Criteria

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Root Cause Analysis Occur Flash on Cav#1 According for this problem occurred from the mold double clamp on the parting line by mold had been sink in the parting line surface with the few flashing and found gap after mold closing until some plastic flow should be agent in these area while injection.

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Root Cause Analysis Escape Flash on Cav#1 1. Have change the temporary operator to support with the lunch time and unknown with the optimize process. 2. Uncontrolled and separate to the finishing process with the cycle time and could be mistaken to operate. Mix Cavity without clarify to finishing Process

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Permanent Corrective Action (PCA) Mold repairing for flashing defect Estimate Mid of May-09 1. Welding and polishing with 3 days 2. Checking and re-texture for core and cavity side 7 days, 3. Testing and submit process change with die sample 7 days. Occur Flashing Area Welding & Polishing Re-Texture for Core & Cavity Side Mold Repair Schedule Items Feb-09 Mar-09 Apr-09 May-09 Mold Shop Cap Full Cap to support with Autumn Model Free-Cap Temp-Action(Cav#1) Built the buffer Stock to Cover 20 May-09 Mold Down to repair 27-Apr Welding and Polishing 28-30 Apr Retexture Core + Cav 2-9 May Trial and submit Die 11 May

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Permanent Corrective Action (PCA) 2. 100% Checking after separate with Cav#1 with the work sequence control (Temporary use while waiting for mold repair until Mold Repairing -------(Done) 20-Feb-09 Occur(Temp) Inform for finishing Area Cutting with left-side Cutting with top side Scrub with cutting holder inspection Inspection + Tag

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Permanent Corrective Action (PCA) 1. Re-training inspector for acceptance criteria ( Done : 20-Feb-2009) Escape Temp Label to Identify and separate for 100% Checked Inspection and separate Cav#1 100% inspection refer the Sample and training with these criteria to acknowledge and understanding within process and outgoing inspection control

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Permanent Corrective Action (PCA) Escape Add Q-Point for the flashing Defect on WI and training operator Adding to the criteria to control and inspection while finishing process Finishing Process after separate Cav # 1 to finishing Bari.

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Verification of Effectiveness of PCA - Monitoring of %Reject for effectiveness ( Until Mold Repairing) Scrub with cutting holder inspection Inspection + Tag Temporary Action Guarantee 100% Welding & Polishing Re-Texture for Core & Cavity Side Die Submission mid of May-09

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Work Flow Diagram(Improve) Injection Finish& Insp Pack Sampling Outgoing Store Production Process Division Failure Majority Production Production IPQC 0.25% OQC 0.25% Warehouse Use 4 Cavity /Shot (20 sec) Separate Cav # 1 to control( Temp) Set the work Sequence to control with Picture Attach the identify Card to indicate Mold Repair Schedule Set the defect sample to clarify 100% check until mold finish. Line Balance Interim & Pernanent Set Sample Activity Mold Improve Work Sequence 100% Inspect