DMAIC approach to improve equipment efficiency

Lau, Kiew Siong (2014) DMAIC approach to improve equipment efficiency. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

In today’s competitive world, the manufacturing sector is facing with various challenges to increase productivity and to reduce cost. In the semiconductor industry, machine costs makes up the largest portion of a manufacturer’s capital investment and hence ensuring maximum utilization of this machine is one of a company’s main concerns. As a machine’s efficiency is directly determined by machine uptime, utilizations and process speed, improving the uptime will directly increase the machine efficiency. This project is based in a back-end semiconductor manufacturing company confronted with consistently high downtime for one of its tester machine. The aim of this study is to increase the efficiency of tester machine; which is achieved by 3 objectives: (1) understand the manufacturing process flow for End of Line (EOL) assembly in the case company (2) determine the tester machine (Taping machine) downtime and (3) proposed solutions by using Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) methodology to reduce the machine downtime. In Define phase, the problem can be determined through understanding of the production process. Next, in the Measure phase, 2 months historical data of the taping machine downtime will be collected from the TFM system. After the data collection, Pareto diagram and Cause and Effect Diagram will be employed to analyze the major causes of the machine’s downtime. Test Head Problem, Flipper Problem and Late Response Time are three major causes to taping machine unscheduled downtime. In the Improved phase, few solutions are proposed to the case company to overcome high machine downtime. For Test Head Problem, the proposed solution are using pogo pin inserting tool to replace worn out pin and applying plug and play concept. The plug and play concept also can be applied in Flipper Problem. For Late Response Time, the proposed solution is to install buzzer triggering system on the taping machine. The Control phase follows to ensure continued and sustainable success with the desired output. The significance of this iv study is proposing solutions to the case company to reduce the taping machine downtime from 2.7 percent to 2.5 percent which set by the case company.

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