FMEA Summary

Accuracy Vs Precision

廢物減少是精瘦的製造業的目標

精瘦的製造業準具體區域為廢減少。
什麼是需要? 什麼是廢物? 顧客要求的不是廢物。

引導精瘦的製造過程的五項原則:
1)定義"價值" : 顧客真正地想要什麼?
2)創造連續的產品流程。
3)使非價值增加的活動減到最少: 這些包括WIP。
4)讓顧客拉扯(Pull) 產品。
5)連續追求改善: 問一切, 和總要求"為什麼?"

TONY LIM 19-Sep-2007 Malaysia
tonycclim@yahoo.com
(+6012-4921811)

什麼是精瘦的製造業系統? Lean Manufacturing

生產要求三個基本的元素: 人、機器, 和材料。(Man, Machine & Material)

精瘦的生產是有效地運用這些三個基本的元素, 減少廢和增長的生產力當改進質量。
實施精瘦的生產是一個長的過程,要求變革包含您的整個企業, 從原材料購買。
在您精瘦的變革旅途期間它是共同體會以下整體表現改善: Result
-行政週期 減少50-90%
-瑕疵 減少50% 每年, 以無次品表現可能
-新產品開發時間 減少75%
-資本化 成本降低50%
-交付前置時間 減少超過75%
-準時交付 改善99+%
-雇員態度 調查結果顯著被改進
-生產力 (銷售每雇員)每年增量15-35%
-存貨 (週轉資本) 減少超過75%

How do you change strategies?

1.) Understand your current strategy, then try to figure out a proactive long-term strategy.
2.) Try to figure out what it is you’re trying to do, accomplish, build and sustain with your business.
3.) Determine what is operating approach that will get you the greatest result you want in the fastest period of time on the most sustaining and enduring basis.
4.) Generate a list of the highest performing, most impressive, sustaining, successful and formidable companies you know of, inside or outside your industry.
5.)Take time to think about what their "big business" strategy really is. What is it they’re trying to do with all the tactics they mount.
6.)Take time to think through how they are doing it or accomplishing it. That’ll break out for you the difference between strategy and tactics. If you’ve done this exercise for one hundred companies, then ask at least a dozen of your friends to do it for you for ten or fifteen companies that theyknow.
7.)Then you can break down a combination of a couple of hundred strategies that you’ve identified and you can evaluate which ones (or composite ones) you can borrow, then combine together to forge your own ultimate replacement business strategy.

Do you train your people?

Every dollar you spend in training will produce at least 20 times return annually
in yield.
Do you train your people?
How often or frequently?
Do you train your selling people in formal professional consultative selling?
Do you train your office staff in all the skill sets needed to perform at superstar levels?
Are they the most effective in efficiency or productivity?

If you can get each of your people 10% better in each of those categories, you’ve just doubled or tripled the effectiveness.
Or you’ll be able to achieve the same result from one half the staff, time or 75% cost.

Reaction to an Out-of-Control Signal (Control Chart)

Reaction to an Out-of-Control Signal

•It is very important to investigate every signal of special-cause variation
–Without attention to the charts, those responsible will begin ignoring the signals
•Necessary to have a planned approach
–Verify that data is correct and has been entered correctly
–Determine if a simple explanation of special cause is available (e.g. parts were dropped)
–Verify process change by taking a bigger sample (>20). Use proper sample size to detect critical difference.
–If process change is real, assess process impact to determine next courses of action:
•Line shut down
•Root cause investigation

Out of control signals:

1)Main Indicators
•any point outside of a control limit

2)Secondary Indicators
•any non-random pattern of points on a control chart
–shift or run
–trend
–stratification
–mixture
–periodicity

DOE Workshop (2 days) 9&10 Oct, Pearl View Hotel, Prai

Course Outline –
Design of Experiment Workshop (2 days)
Venue : Pearl View Hotel , Prai

Date : 9 & 10 Oct 2007

Time : 9am~5pm

Fee : RM500 per person. (* special discount for group registration)

INTRODUCTION

DOE is now recognized as a key strategic element to help organizations remain competitive and profitable in today's business climate which demands consistency and quality.
A Design of Experiment (DOE) is a structured, organized method for determining the relationship between factors affecting a process and the output of that process.
It is a systematic methodology that dramatically improves industrial products and processes thus enhancing productivity and reducing costs. Input factors are varied in a planned manner to efficiently optimize output responses of interest with minimal variability.
This training provides a comprehensive exposure to the use of powerful DOE techniques for improving and optimizing any process. During this workshop, you will learn how to set up and run basic factorial and screening experiments; how to analyze experimental outcomes; identify significant effects on process performance and consistency; and identify factors for further study or implementation. Then, in a workshop environment you will design and conduct experiments.

Duration

2 days (9am-5pm)



OBJECTIVES

After the training, the participants will be able to:

· understand the advantages of using experimental design over trial and error methods
· set up and run basic factorial and screening experiments
· analyze experimental outcomes
· identify significant effects on process performance and consistency
· identify factors for further study
· optimize the output performance of a process or product
· use relevant techniques & tools for DOE implementation.
· correct the mistakes or overcome the problems encountered during DOE implementation.

WHO SHOULD ATTEND

This course is designed for those managers, engineers, & professionals who
intend to apply DOE for process optimization.
responsible for developing or improving products and processes.
No previous exposure to designed experiments is required.

COURSE CONTENT

Day 1 – 9.00 am – 5.00 pm
Module 1 : Introduction to DOE
· What is DOE?
· Why do a designed experiment?
· Try and error method and OFAT (One-Factor-At-A-Time)
· Types of experiment
· Steps for implementing DOE
· Practical examples
Module 2 : DOE Terminology
· Statistical assumptions for DOE
· Understanding on process variation & p value
· Sampling strategies
· Randomization
· Blocking
· Main Effects and Interactions
· Coded setting
· Un-coding the setting
· Introduction to ANOVA

Module 3 : Two factors factorial design
· Why do we need to use 2k factorial experimentation?
· 2k Vocabulary
· Steps for DOE Analysis
· 2k Standard Order Designs
· Calculating main effects
· Calculating interactions
· Adding Center Points
· Adding Blocking
· 2k Example and Exercise
· Interpretation of results and necessary actions

Day 2 (9.00am- 5.00pm)
Section 4 : Three-Factor Full -Factorial Design
· Graphical Interpretation of Effects and Interactions
· Statistical Concepts
· Determining Statistical Significance
· Interpretation of results and necessary actions
· Design and Analysis
· Practical workshop

Module 5 : Fractional Factorial Design
· Fractional Factorials
· Defining Relation
· Confounding
· Resolution
· Factor Assignment
· Interpretation of results and necessary actions
· Practical workshop
Module 6 : Introduction To Advanced DOE
· Advanced DOE
· Response Surface Methodology (RSM)
· Multiple Responses Optimization
· Taguchi method




Trainer profile:

1. Mr. Tony Lim
Tony Lim, Master of Science (USM, Penang)
Tony Lim is a certified quality auditor and is a Training Specialist by profession.
He is a multilingual facilitator with more than 5 years of consulting and training
experience in ISO 9000 quality management, six sigma deployment, statistical
process control and lean manufacturing. He has more than 15 years of
experience in quality system management, 5 of them as a quality manager for
one of leading MNC.
He has often been invited to conduct training for various manufacturing
companies in Asia Pacific Region.
His main accomplishments were setting up and implementing the ISO 9000
Quality Management System and Six Sigma Deployments for various
manufacturing companies.

2) Mr Roshidi Mat Rejab
Roshidi, Master of Mechanical Engineering (Old Dominion University, Norfolk, U.S.A in 1987)
Roshidi has spent more than 16 years in world leaders manufacturing environment as key person of operation team. Besides working in major international companies in Malaysia, he has also worked abroad; for instance at Intel,Phoenix plant, Arizona, U.S.A.(1988~1992).
Experiences and educations gained abroad lifted up his way of thinking towards a more global manner, as demonstrated in his performance at work.
Over the past four years, he has facilitated more than 100 practical workshops in Asia Pacific region dealing with principles of Lean manufacturing, overall equipment effectiveness, DOE, FMEA, value stream mapping, visual factory, Genba Kaizen, kanban systems, setup reduction, and total productive maintenance (TPM).