Using visual management tool to error proof WIP lots withdrawal in semiconductor manufacturer

Wong, Kuan Lih (2015) Using visual management tool to error proof WIP lots withdrawal in semiconductor manufacturer. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

In high technology world, the industry is competing against each other to increase productivity, quality, reduce cost and meet customer satisfaction. Semiconductor industry which is a major contributor to Malaysia’s economy must stay abreast with challenges and find better ways to achieve perfection. This project is based in a backend semiconductor manufacturing company which is facing problem with operators’ errors in picking wrong lot (WIP product) at the bottleneck machine. The operators’ error in picking wrong lot impact the production line run without based on schedule. It alters production efficiency and subsequently will increase cycle time of the production line. The aim of this study is to reduce operators’ error in picking wrong WIP lot and ensure operator pick the WIP lot base on schedule, which is achieved by 3 objectives: (1) identify the causes of operators’ errors in picking the wrong WIP lot, (2) redesign a FIFO cabinet and develop a visual management tool to reduce operators’ errors in picking the wrong WIP lot and (3) implement the FIFO cabinet with visual management tool in case company and to validate the benefits. FIFO cabinet with five S, color code and SOP are chosen to be implemented in the case company as to reduce operators’ error and ensure they are picking WIP lot base on schedule. The result for before and after implementation of FIFO cabinet with five S, colour code and SOP are collected, validated and discussed. The significance of this study is to reduce operators’ errors in picking wrong WIP lot.

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