TV
DENGAN METODA SIX SIGMA
DI PT LG ELECTRONICS INDONESIA
A R I P I N
2002 - 21 140
TEKNIK INDUSTRI
UNIVERSITAS INDONUSA ESA UNGGUL
2004
Samples average :
LSL
USL
X=
Xi
i=1
=s=
( Xi - X )
i =1
n-1
Z =
Kemampuan 3s
Z =6
x -
USL
LSL
Kemampuan 6s
meningkat
DEFINE
Validate problem
/ process
Measure key
problem
Current condition
Standardize
solution
Establish standard
measure to
maintain
performance
CONTROL
IMPROVE
MEASURE
Screening potential
factor
Identify vital few root
causes
Validate hypothesis
ANALYZE
Geser
menuju
Target
Shifting/bergeser ke Target
& Mereduksi Variasi
T
USL
USL
T
USL
USL
Object
dari 6
adalah
Shift(geser)
ke target
Menurunkan
Variasi
USL
USL
Turunkan
Variasi
PT LG ELECTRONICS INDONESIA
2004 06 14
Project
Period
Quantity
Target
Theme
Outline
Analysis
Improvement
Control
Current
Target
Improvement
Ratio (%)
840 PPM
0 PPM
100 %
Status
&
Problem
WIRE HOLE
WIRING CROSS
CHECKING PROSSES
Name
Member
Role
Aripin
$29000
Customers
Needs
Definition
Telp.
QA
212
100%
Amount
Of target
(US$/Year)
$0
Before
Dept
2 - 22
After
Problem Situation
Management policy said we have reduce field claim.
Data field claim show No Power is cause biggest
than other.
No power is TV Set have no supply voltage. It show by not light of Indicator power and no display on tube.
No power can caused by parts, like power cord, SMPS Transformer, IC, FBT, Transistor and others.
SMPS Transformer have function as divider power voltage to several sub circuit or part like FBT, IC, and others.
If SMPS not function, it cant supply voltage to parts or sub circuit .
No Power
No Sound
Knowledge
Picture NG
CPT NG
10%
15%
Sound
SoundNoNG
15%
A/V NG
No Power
42%
8.4%
Screen
16%
8%
27%
IC
5.2%
Crystal
3.4%
FBT
2.0%
Others
840 PPM
100%
13%
Diode
Resistor
70.2%
6170VMCBO1L
15%
Transistor
12%
Target
29%
SMPS
Fuse
14%
26.3%
6170VMCBO1K
0PPM
Others
2.0%
3.6%
3.5%
Before
3 - 22
After
Theme Selection
Big Y
Little y1
Little y2
Improve
Improve
TV
TV Quality
Quality
Attribute
Attribute
30% SCR
Reducing
Reducing
Knowledge
Part
TYPE
PIC
Status
Crack, Ball
Opt. Skill, Ability
Wire Connection
Handling
Handling
Opt. Skill, Ability
Wrong Connection
Handling
1P1P
LQC
Finished
1P1P
LQC
On Progress
1P1P
1P1P
IQC
On Progress
Production On Progress
IIC
1P1P
Production Finished
Production On Progress
IIC
IQC/Prod
Finished
AGC Circuit
1P1P
IQC
On Progress
1P1P
Production On Progress
Antenna
How to Use
No connection
1P1P
OQC
On progress
How to Use
OQC
Product Spec
Electricity
How to used
Plug Connection
1P1P
1P1P
On Progress
On Progress
Environment
Environment
IC
Transistor
CPT
Chassis
Soldering
Process
Little y3
Adjustment
Speaker Connection
PWB Crack
Loosen Part
Bad Wiring Connection
PWB Short
Front Cabinet Dented
AGC Circuit
Bad System Connector
FBT
Tuner
Speaker
SMPS Trans
Reliability
Screen Focus, DYC,PRT
ABL Short
AGC, No Ruster
No Sound Problem
No Power
Fuse
Capacitor
Un Connect
Reliability
Reliability
Resistor
4 - 22
1P1P
OQC
OQC
1P1P
1P1P
1P1P
OQC
IQC
IQC
On Progress
On Progress
Finished
1P1P
IQC
Finished
IIC
1P1P
IQC
IQC
Finished
On Progress
1P1P
IIC
IQC
IQC
Finished
Finished
1P1P
IQC
On Progress
On Progress
Process Mapping
SAMWHA
Process
LGEIN IQC
LGEIN LQC
LGEIN OQC
R&D
Appearance
Patrol
ELT
Purchase
Dimension
Performance
LTLT
IQC
Structure
Final
Inspect
Reliability
Product
Production
Performance
LQC
Assembling
OQC
Reliable Part
High defect
SMPS no power
At LGEIN production
Find Out what is
the Main Cause of
Problem
Selecting Best
Condition
for reliable Part
OS&D
5 - 22
SMPS
8
10
14
13
SMPS Component :
Core
Bobbin
Wire
Insulation
Tape
Shield
12
Potential Short
Area
6 - 22
Clarification Of Y
Kind of defect by SMPS
MARKING NG
APPEARANCE
Master
Signal
RUST
ISOLATION NG
SMPS
DEFECT
DIMENSION
Test
Signal
Test Signal
P/P OVER
NG SIGNAL DISPLAY
WIRE SHORT
PERFORMANCE
Master
Signal=
OK SIGNAL DISPLAY
No
Power
BROKEN
TURNS
Indicator
TV Set Power OK
TV Set No Power
7 - 22
Agreement Analysis
21
22
23
24
25
Attribute
Pass
Pass
Pass
Fail
Fail
Pass
Pass
Fail
Fail
Try 1
Pass
Pass
Pass
Fail
Try 2
Pass
Pass
Pass
Fail
Fail
Pass
Pass
Fail
Fail
Within Appraisers
Fail
Pass
Pass
Fail
Fail
OPR 2
Try 1
Pass
Pass
Pass
Fail
Try 2
Pass
Pass
Pass
Fail
Fail
Pass
Pass
Fail
Fail
Assessment Agreement
OPR 3
Fail
Pass
Pass
Fail
Fail
Try 1
Pass
Pass
Pass
Fail
Fail
Pass
Pass
Fail
Fail
Try 2
Pass
Pass
Pass
Fail
Within Appraisers
Fail
Pass
Pass
Fail
Fail
96
# Inspected
# Matched
Percent
25
25
100.00
(86.09, 100.00)
OPR-2
25
25
100.00
(86.09, 100.00)
OPR-3
25
25
100.00
(86.09, 100.00)
90
88
88
OPR-1
25
25
100.00
(86.09, 100.00)
OPR-2
25
25
100.00
(86.09, 100.00)
OPR-3
25
25
100.00
(86.09, 100.00)
Assessment Agreement
# Matched
Percent
25
100.00
OPR-1
OPR-2
Appraiser
OPR-3
25
OPR-3
95 % CI
Between Appraisers :
# Inspected
86
OPR-2
Appraiser
Percent
92
# Matched
95.0% CI
Percent
95 % CI
# Inspected
SHORT TEST
94
90
OPR-1
OPR-1
Appraiser
96
86
98
92
Name of product:
Misc:
100
98
94
Date of study:
Reported by:
Appraiser vs Standard
95.0% C I
Percent
100
Percent
Sample
1
2
3
4
OPR 1
Percent
Known Population
95 % CI
(86.09, 100.00)
8 - 22
= 124 : 147595
DPO
0.04
DPO
= 8.4E-04
Z Value
= 3.1 + 0.04
= 3.14
9 - 22
8.45E-04
Potential Factor
wire
Material
Short
(No
Power)
Dielectric
Breakdown
Hole
Core
Varnish
Press
Turn wiring
Space
Home pin
Finishing
Method
10 - 22
D/B : 2250 V
Sample
2250
Decision
Sample
2250
Decision
2235
FAIL
14
1850
FAIL
1990
FAIL
15
2230
FAIL
Sample
Sample p
2010
FAIL
16
1990
FAIL
2240
FAIL
17
2010
FAIL
25
0.000000
2125
FAIL
18
1890
FAIL
19
25
0.760000
2150
FAIL
19
2110
FAIL
2250
FAIL
20
2225
FAIL
1990
FAIL
21
2000
FAIL
FAIL
22
2010
FAIL
23
1995
FAIL
2000
10
2230
11
2000
FAIL
Sample
2250
1985
FAIL
1960 1
FAIL5430
2
4795
12
13
D/B : 2250
V
FAIL
24
Decision
25
PASS
1890
FAIL
Sample
2250
1885
FAIL
14
4300
-0.76
(-0.927414, -0.592586)
PASS
15
5800
PASS
4500
FAIL
16
7800
FAIL
5350
PASS
17
7900
PASS
6000
FAIL
18
4600
FAIL
5100
PASS
19
5800
PASS
5700
PASS
20
5500
PASS
5700
PASS
21
7500
PASS
4500
PASS
22
7900
PASS
10
5000
PASS
23
5600
PASS
11
4100
PASS
24
4500
FAIL
12
4250
FAIL
25
6500
PASS
13
5600
PASS
Z = -8.90
P-Value = 0.000
11 - 22
P/H : 5
Test and CI for Two Proportions
Sample
Decision
Sample
Decision
PASS
14
PASS
Sample
PASS
15
PASS
PASS
16
PASS
PASS
17
PASS
PASS
18
PASS
PASS
19
PASS
PASS
P/H : 205
PASS
PASS
Sample
PASS 1
21
5
22
7
1
Decision
0
PASS
10
PASS 2
11
PASS 3
23
7
24
8
12
PASS 4
13
PASS 5
6
Sample p
25
25
1.000000
14
25
0.560000
PASS
Sample
PASS14
Decision
PASS
0
PASS
0
FAIL
PASS15
PASS16
PASS
FAIL
25
7
1
FAIL
PASS17
PASS
PASS
18
PASS
FAIL
19
FAIL
PASS
20
FAIL
FAIL
21
PASS
PASS
22
PASS
10
PASS
23
FAIL
11
10
FAIL
24
PASS
12
11
FAIL
25
PASS
13
10
FAIL
0.44
(0.245420, 0.634580)
P-Value = 0.000
12 - 22
Varnish
Sample p
22
25
0.880000
21
25
0.840000
Sam ple
Varnish
Decision
Sam ple
Varnish
Decision
PASS
14
PASS
PASS
15
PASS
PASS
16
PASS
PASS
17
PASS
PASS
18
PASS
FAIL
19
PASS
PASS
V
Non Vr.22 DecisionV
NV 23
PASS V
PASS
Sample
FAIL
10
11
12
13
PASS
20
No
Varnish
PASS
21
Sample
PASS
1
PASS
(-0.152036, 0.232036)
Decision
14
PASS
15
PASS
NV
PASS
NV
PASS
2
FAIL
3
PASS
NV 24
NV 25
PASS V
PASS
NV
PASS
16
PASS
17
NV
4
PASS
5
NV
PASS
NV
PASS
18
NV
PASS
NV
PASS
19
NV
PASS
NV
PASS
20
NV
FAIL
NV
PASS
21
NV
PASS
FAIL V
0.04
NV
PASS
22
NV
PASS
10
NV
FAIL
23
NV
FAIL
11
NV
PASS
24
NV
PASS
12
NV
PASS
25
NV
PASS
13
NV
PASS
Z = 0.41
P-Value = 0.683
13 - 22
Sample p
22
25
0.880000
PASS
24
25
0.960000
PASS
PASS
PASS
Sample
Space
Decision
Sample
Space
Decision
PASS
14
PASS
PASS
15
PASS
PASS
16
PASS
17
PASS
18
PASS
PASS
Sample
PASS 1
PASS 2
10
11
12
13
Space19
Sample
No20Space
21NS
22NS
23NS
24NS
25NS
S
Decision
S
PASS
S
PASS
S
PASS
S
PASS
S
PASS
PASSSample
NS
PASS
19
NS
PASS
NS
PASS
NS
10
No Space
Decision
PASS 14
PASS 15
NS
PASS
NS
PASS
PASS 16
PASS 17
NS
PASS
NS
PASS
NS
PASS
NS
PASS
20
NS
PASS
21
NS
PASS
PASS
22
NS
PASS
NS
PASS
23
NS
PASS
11
NS
PASS
24
NS
PASS
12
NS
PASS
25
NS
PASS
13
NS
PASS
PASS 3
PASS 4
PASS 5
PASS
6
No Space
PASS 18
14 - 22
Space
- 0.08
(-0.152036, 0.232036)
P-Value = 0.297
Analyzing Finishing Method by Comparing whether Parallel winding and Cross Winding contribute a significant
effect for wire short.
Parallel
Sample
Cross
Decision
Sam ple
Cross
Decision
PASS
14
PASS
Sample
PASS
15
FAIL
FAIL
16
FAIL
PASS
17
PASS
PASS
18
PASS
19
FAIL
FAIL
Cross
10
11
12
13
FAIL
PASS Parallel
Sam ple
PASS
SampleFAIL Parallel
22PASS
23PASS
C
C
3 PASS
4 FAIL
24PASS
25PASS
5 PASS
7
8
Decision
14 FAIL
15 FAIL
PASS
PASS
16 PASS
17 PASS
PASS
PASS
PASS
18
PASS
FAIL
19
PASS
PASS
20
PASS
PASS
21
PASS
PASS
22
PASS
10
PASS
23
PASS
11
PASS
24
PASS
12
PASS
25
PASS
13
PASS
C
C
Sample p
14
25
0.560000
24
25
0.960000
Cross
20
P
Parallel
21
Decision
1 PASS
2 FAIL
-0.4
(-0.609193,
P-Value = 0.000
Dielectric
Breakdown
Vital View
Hole
Vital View
wire
Material
Short
(No
Power)
Core
Varnish
Press
Turn wiring
Space
Home pin
Cross
Method
Need improved
Not need improved
16 - 22
Vital View
50
40
H+
Opt.
Condition
DB
DB DB DB +
DB +
DB +
DB +
DB DB -
PH
PH +
PH +
PH +
PH +
PH PH PH PH -
MTD
P
C
P
C
C
P
P
C
Pass %
0
0
50
40
70
100
0
0
100
P
MTD
70
H-
C
DB -
DB
DB +
Optimum condition :
Dielectric Breakdown : 2250 V
Pin Hole : 5 hole / 5 m
Method Finishing : Parallel
17 - 22
Improvement
Improvement on Finishing Method at Samwha Process
Before :
4 M Change Report
Cross Method
Parallel Method
18 - 22
Improvement
Improvement on Inspection Checking Method
IQC Samwha
Before
Before
After
After
Supplier
Supplier
Delivery
Delivery
Incoming
Sampling
Inspection
(Conventional)
OK
Storage Area
Incoming
IQC
Appearance
Size
NG
Sampling
Content
IQC
Appearance
Size
5 m each roll wire
( test hole & D
Breakdown )
Inspection
( > 5 hole/5m, NG )
Dielectric Breakdown test
Check hole
&D
Breakdown
NG
OK
Storage Area
19 - 22
Maintain CTQ
To keep good condition, we do :
Dielectric breakdown and hole wire control at wire vendor ( monthly )
Wire hole test before to production
Item CTQ Control
QC and Process Irregular Audit at Supplier
Total Inspection Part (100% Short Test)
CTQ
D/B
Inductance
Resistance
Control
Control
Control
I Chart of D/ B
I Chart of INDUCTANCE
UCL=549.08
155.0
_
X=529.2
530
520
Individual Value
_
X=5.316
5
UCL=158.14
157.5
540
Individual Value
Individual Value
I Chart of RESISTANCE
550
UCL=7.135
_
X=152.4
152.5
150.0
147.5
LCL=3.497
LCL=146.66
510
3
2
10
12
Observation
14
16
18
20
LCL=509.32
2
10
12
Observation
14
20 - 22
16
18
20
145.0
2
10
12
Observation
14
16
18
20
Saving Cost
Part production on March ~ May 04 are 245915 EA, SMPS Transformer defect: 1 ea
DPU
= 1 : 184259 = 5.427E-6
No Power by SMPS
(70.2%
)
840 PPM
4.64
423
BOIL
(26.3%
)
56
BOIK
OTHE
RS
Part No
Improv
e
Defect PPM
Defect PPM
1128
No Power by SMPS
4 PPM
5.97
BOIL
Part No
SAVING COST
HISTORY :
October ~ December 03 :
Analysis cost : $ 1000
$29000
$0
Before
BOIK
After
OTHER
S
THANK YOU
22 - 22