Application Study Of Lean 6 Sigma To Improve PCB Scale Value And Establish Automatically System In Company A

Along with the development of the technology,the PCB which is used on different kinds of the electrics and electronic appliances devices for electrical connection is required more complicated design.Because the design of PCB is more and more complicated,the scale factored out of tolerance issue which was ignored in PCB manufacturing is required to be monitor by the customer.A Company has been the PCB manufacturer lead for long time.When the customers require to monitor the scale factor of the PCB suddenly,A company has not good solution for the scale factor controlling because the number of affect factors is too many,the affect many processes.Although A company have the best technology in PCB manufacturing and has many experienced engineers.It's hard to control the scale factor to meet the customers' requirement,meanwhile to control the cost.Six sigma management is the most effective quality management currently.Under the guidance of 6 themes of six sigma,there is a specific process of six sigma: DMAIC.From the analysis of the demand of the customers,to analyze the current performance of scale factor controlling in A company,and the gap between the performance in A company and the customers' requirement.To find the factors which affect the scale factor,to find the solution.Meanwhile,also using lean,to delete the un-value added process,make the process standard,simplify the process,using more error proof method,control and maintain the effeteness of the improvement.The team of six sigma is made of the engineers from different processes.They study the performance of the scale factor from zero,using brainstorm,fish bone to find the possiblefactors.Analyze all the possible factors,collect the data,and shrink the range of the possible affective process.For the process which is defined the key process,collect the data again,to arrange the test and do the verification.To improve the parameter and process in the premise don't influence other PCB's characteristics.From the unsuitable control process,to improve the parameter,re-define the control rule,improve the process.And also modify the engineering system which is related to the scale factor control,to avoid the human error happen which will make huge amount of PCB scrapped.Meanwhile,according to the current A company production system,engineering system and monitor system,to develop a specific auto scale control system.The system is not only with alarm function,and also give the feedback and can calculate the scale factor compensation faction.The system doesn't not only avoid the human error made by the operators who escape the bad scale value PCB to the next station.And also can send the alarm message to the related engineers when the trend of scale value is worse.The advised scale value adjustment value will be send to the engineers too.and the system can ignore the data of the lot which is not used the latest scale factor pre-setting by the calculating in the background.Which can reduce the work loading of the engineer when they need fact to huge amount of data in different data bases? And increase the accuracy and effectiveness.For some special products,they cannot be controlled by the auto scale value system,but in order to avoid the bad scale value PCB escaped to the customers.Add some Manu-monitor method and also full monitoring system.And also add some auto method in the monitoring system;control the scale value on time,to meet the customer requirement as much as possible.