Improve Broken Wire of LTC and LTD Series

The customer complained and returned the goods for sorting due to the dead segment caused by broken wire. We have optimized new parameters based on experiments to improve the result and reduce the CCR and FRR of the broken wire.










What? Dead segment due to broken wire.Where? Customer complaints.When? Jun. 2007 to Dec. 2007.How much? FRR 2 cases, and CCR > 20 cases.How do you know? FRR & CCR.










Dead segment due to broken wire:

Working method and control tooling at A/B process. Control as below.

WI – ENG – 30290-006.
Collect the DPPM result at IPQC gate.










Results Summary

Monthly Cost avoidance (NTD)Aug. 2008: 1,862,321Sep. 2008: 915,656Oct. 2008: 939,709Nov. 2008: 935,370Dec. 2008: 931,704Jan. 2009: 938,639Feb. 2009: 962,167Mar. 2009: 963,108Apr. 2009: 949,041May 2009: 936,162Jun. 2009: 942,483Jul. 2009: 956,768
Cost Savings

Actual Savings in last 3 months (2009/05-07): 2,835,413 NTD.
Actual Savings in one year (2008/08-2009/07): 12,233,128 NTD.(IPT Project No.: IPTH08Q20013)











Benefit1. Cost avoidance.2. Team work.3. Improve quality.4. Avoid customer claim.5. Reduce unit loss in production.
Contents1. Brainstorming.2. Confirm assumption by DOE and optimization.3. Follow instructions. Control and maintain methods.
Technology & InnovationChange from old working concepts to 6 Sigma concepts (DMAIC).
Value for duplicateWe can duplicate this project for all ND products.









OPTO_Improve Broken Wire of LTC and LTD Series.ppt









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